boeing factory tour closed

Simple Flying

Boeing to reopen popular everett factory tours.

The Everett factory first broke ground over 55 years ago in 1966.

• Boeing's famous factory in Everett, Washington is reopening its tours after being shut down since 2020 due to the COVID-19 pandemic.
• Visitors can expect enhancements to the tours, including a new route through the factory and updated visual components.
• The factory is globally known for producing various Boeing aircraft, with the next generation Boeing 777X set to join the production line after certification.

On September 28, Boeing announced it would reopen tours for its famous factory in Everett, Washington. The factory is well-known for producing various Boeing aircraft over the years. Boeing revealed that tickets are now on sale for factory tours beginning on October 5.

Famous factory tours

The Everett factory has seen over six million visitors since it began offering tours in 1968. However, the tours have been shut down since 2020 due to the COVID-19 pandemic. Now, with the tours beginning again, visitors will see various enhancements from the typical tours that visitors have seen in the past. This includes a brand-new route through the factory and updated visual components.

The Boeing Future of Flight General Manager, Christi Medlyn, spoke about opening tours. Medlyn said in a statement,

"We are thrilled to reopen our factory tour experience to visitors who want to see how Boeing airplanes are assembled and learn about the company’s role as a global leader in aviation, With the rebound in travel and tourism, we are pleased to once again share this exclusive look into one of the world’s most interesting factories."

A typical tour of the factory lasts around 80 minutes. Visitors can walk through the famous factory and get a behind-the-scenes look at the production line as well as learn about the history of the production site in Everett. The tour begins in the Boeing Future of Flight Museum, which showcases the various aerospace attractions, Boeing products, and the company's commitment to advancing the aviation industry. Visitors can then walk through the factory's network of underground tunnels and visit the observation balcony to see the production line in action, which is currently producing the Boeing 777 .

Globally known factory

The factory, which sits at the Northeast corner of Paine Field, is known across the world for producing a wide range of Boeing aircraft. Since its groundbreaking in 1966, the factory has produced the 747, 767, 777, and the 787 Dreamliner.

The factory is also recognized as the largest building in the world by volume. It takes up 98.3 acres and has a 98 million cubic feet footprint.

Discover more aviation news with Simple Flying.

Everett producing the 777X

After the Boeing 777X completes the certification process, it will join the Everett factory production line. The next generation widebody aircraft is hoping to begin deliveries in 2025 after the certification process has experienced significant delays. However, Boeing has already received several orders for the next-generation aircraft.

The aircraft's launch customer is Lufthansa , which ordered 27 Boeing 777-9s. The airline is set to replace some of its aging aircraft, such as the Boeing 747, with the new aircraft.

The largest order of 777Xs is by Emirates . The airline ordered a total of 115 aircraft, set to replace some of the older 777 variants. The airline also famously only operates 777s and Airbus A380s, although it is set to receive Airbus A350s in the future.

Other global airlines such as Qatar Airways, Singapore Airlines, All Nippon Airways, Air India, and British Airways among others have also ordered the aircraft.

Have you ever taken a tour of Boeing's Everett factory? Let us know your stories in the comments.

Boeing Tours

Boeing future of flight and boeing everett factory tour.

Boeing Future of Flight is one of Washington State's premier aerospace attractions, welcoming guests to enjoy the Boeing Everett Factory Tour, Gallery, Sky Deck and Boeing Store. Boeing Future of Flight is located in Mukilteo, WA next to Paine Field and the Boeing Everett Factory, just 25 miles north of downtown Seattle.

Step inside the world's largest factory for a behind-the-scenes look at the Boeing Everett Factory and 777 assembly line. Each tour is an 80-minute guided experience with a front row view of current airplane production, the Everett site’s history, and the central role it plays in the future of commercial aviation. Tours are available Thursday–Monday.

Learn more about the Everett, WA tour

James S. McDonnell Prologue Room Air and Space History Exhibit in St. Louis

The James S. McDonnell Prologue Room Air and Space History Exhibit showcases the pioneers of aviation, their achievements and those of the thousands of workers who turned dreams into reality. The Prologue Room is located in the Boeing-St. Louis headquarters adjacent to Lambert-St. Louis International airport. The Prologue Room is open for self-guided tours weekdays during June, July and August only. Guided tours are available to groups of 10 or more throughout the year.

Learn more about the St. Louis tour

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Boeing’s iconic Everett factory tour to resume in October

After a three-year hiatus, tours of the Boeing Company’s enormous jet assembly plant are back at Paine Field.

• Thursday, September 28, 2023 1:05pm
• Local News Aviation and space Mukilteo Paine Field

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Boeing workers in the Boeing factory at Paine Field in Everett, Washington. (Andy Bronson / The Herald) Boeing workers in the Boeing factory at Paine Field in Everett, Washington. (Andy Bronson / The Herald file)

Patrons view the 787 exhibition at the Boeing Future of Flight Museum at Paine Field on October 8, 2020. (Kevin Clark / The Herald)

As a call to line up for the Boeing Assembly plant is called out, a tourist runs past a display of Boeing airplanes at the Future of Flight Museum in Everett, Washington. (Andy Bronson / The Herald)

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Go behind the scenes at boeing: factory tours are back.

Boeing's Everett factory, renowned as the largest building in the world by volume, once again opened its doors to the public on October 5

by Enrique Perrella

November 1, 2023

Photo: Courtesy of Boeing Commercial Airplanes

After a lengthy hiatus due to the COVID-19 pandemic, the Boeing Factory Tours are back, offering aviation enthusiasts and curious minds a chance to witness the magic of aircraft production.

For years, the Boeing Factory Tour has been a sought-after experience, attracting more than six million visitors from around the globe since its inception in 1968. The tour provides a glimpse into the fascinating world of aviation, with a behind-the-scenes look at the assembly line of iconic Boeing aircraft, which included the 747, 767, 777, and 787 Dreamliner.

Christi Medlyn, Boeing Future of Flight general manager, shared the excitement surrounding the reopening with Business Traveler USA .

“We’ve been closed for the tour portion of the experience for three and a half years. In the meantime, we invested in this space to give people a great brand experience for Boeing. It’s not just about airplane manufacturing; it’s about the full enterprise,” she explained.

A Renewed Factory Tour

Boeing’s Future of Flight location has undergone a transformation over the past few years to complement the factory tour. It now offers an immersive experience that covers various aspects of Boeing’s operations, including sustainable fuels, autonomous flight, and satellite technology.

In addition, hands-on activities and STEM learning opportunities have been introduced, allowing visitors to engage with drones and robots.

Visitors will notice several enhancements to the Boeing Factory Tour experience. The new route through the factory offers a unique perspective, taking guests from the Boeing Future of Flight Museum to the massive Everett factory, where tens of thousands of employees support airplane production.

The tour also includes access to the site’s underground system of factory tunnels and an observation balcony providing an exclusive, sweeping view of the current 777 assembly line where Boeing’s future flagship, the 777X, will also be manufactured. Lufthansa and Emirates are the first two airlines expecting to take delivery of the new variant of the Triple Seven.

Photo: Boeing 777X. Courtesy of Boeing Commercial Airplanes

Furthermore, visitors are treated to a comfortable bus tour that takes them through various sections of the airport tarmac. The journey starts from the area where new planes are fueled for the first time and continues to where Boeing 737 fuselages arrive on train wagons from Wichita, Kansas.

Sometimes, brand-new Boeing 777s without engines can be spotted, and other rare planes like Boeing 767 military tankers can be seen as they are prepared for delivery. During every portion of the tour, a knowledgeable guide provides detailed explanations of every aspect and responds to any questions from curious visitors.

However, the tour isn’t the only attraction. Boeing Future of Flight features the Boeing Gallery, showcasing nearly 150 past, current, and future Boeing products and services, including the intriguing Passenger Air Vehicle (PAV) or personal flying car.

The Above and Beyond exhibit offers immersive simulations, and visitors can snap selfies with the Destiny Module from the International Space Station.

The open-air Sky Deck provides breathtaking views of Paine Field, the factory, and the enchanting North Cascade Mountains in the distance. It’s not unusual to spot brand-new planes parked on the deck, preparing for their journey into the skies.

And for those looking to take home a piece of aviation memorabilia, the Boeing store offers a wide range of souvenirs, from sweatshirts to scale model jets, coffee mugs, and vintage Boeing pilot jackets for kids and adults.

Overwhelming Response

The reopening of the Boeing Factory Tours has been met with overwhelming demand. Visitors have expressed their excitement and appreciation for the improved experience.

“It has been overwhelmingly positive, as we have been sold out every day. The pent-up demand and excitement around our product has been contagious. We are pleased with the positive visitor reviews received so far,” Christi Medlyn said.

“We’ve invested in every aspect of the experience, from the script to the exhibit content. We’ve added new elements and updated the storytelling.”

“Even though the experience is a bit different from the last time, we have made significant investments in every aspect. You will see the difference even while walking down the booth hallways,” Medlyn added.

Focus on the Boeing 777

While the tour has shifted its focus from the 747 to the 777 experience, it continues to captivate visitors, old and new, with its rich history and innovations in the world of aviation.

With the entire assembly line for the 787 Dreamliner now operational at Boeing’s South Carolina plant, the facility at Paine Field is exclusively dedicated to the Triple Seven family of planes. This includes the present 777 Freighter, along with the new 777X, along with the occasional 767 Freighter.

“After the 747 and the 787 were no longer being manufactured in Paine Field, we had to alter our route,” Medlyn explained. “As a result, we are now focusing on improving the 777 experience while incorporating new elements that highlight the entire family of Boeing Commercial Airplanes. We aim to discuss sustainability and introduce fresh perspectives to our storytelling.”

“So, we looked at everything from the script to the exhibit content. We added a little bit of Boeing history that you’ll see in the theater experience through a video at the beginning of the tour.”

Whether you’re a seasoned aviation enthusiast or just curious about the marvels of flight, the Boeing Factory Tours are ready to deliver an unforgettable experience you’ll be eager to share with your friends for months to come.

So, mark your calendars, aviation fans, because this is a rare opportunity to step inside the world of Boeing, where dreams of flight become reality. The Everett factory, Boeing’s crown jewel, is ready to inspire and educate once again.

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Boeing factory tour.

Take the amazing Boeing Factory Tour near Seattle, to see jets under construction (currently closed ).

The Boeing Factory is located 20 minutes north of Seattle in Everett.

Tour the Boeing Factory to see jets under construction, inside the world's largest building spread over 4.3 million square feet. Seattle has a rich aviation history, and Boeing was founded here in 1916. 

The Boeing Factory Tour is located at  8415 Paine Field Boulevard, Mukilteo, WA 98275 .

Check tickets & hours .

10 Things to Know about the Boeing Factory Tour

1. The Boeing Factory Tour is a 90-minute tour of the factory floor , where the jets are being constructed. 

2. Tickets sell out quickly, so advance purchase tickets are highly recommended , and arrive 30 minutes prior to your tour time.

3. No photos are allowed on the Boeing Factory Tour , but here's a sneak peak of  what you'll see .

4. The Boeing Factory Tour runs along a walkway that sits high above the commercial assembly plant . There are two sets of steep steps to climb, and two freight elevators to ride in.

5. See the Boeing Dreamliner, 747, 767, 777 and 787's under construction!

6. All bags and handhelds must be placed in a locker.

7. Kids must also be over 4-feet tall to take the tour.

8. The Boeing Factory Tour also gives you access to the outdoor Sky Deck,  with great views of Paine Field and the Dream Lifter Operations Center, where you can watch Dream Lifters taking off and landing.

9.  Complete your visit by stopping by the  cafe  and  gift shop.   The gift shop has some great STEM toys. 

10.  After the Boeing Factory Tour, continue to the  The Future of Flight Museum.  The museum boasts interactive exhibits on Boeing and commercial flight.  Sit inside a cockpit, ride in a flight simulator, and experience the signature interior of a Boeing plane.  Marvel at a full-scale model of a jet engine.  

Some of the exhibits at The Future of Flight Museum.

Step inside a Boeing plane!

Know before you go

• Address:  8415 Paine Field Boulevard, Mukilteo, WA 98275.
• Tour times:  here .  
• Tickets:    here .  
• Kids:   Must be over 4 feet tall.
• Cameras:  No.
• Cafe:  Yes.

Fun things to do near the Boeing Factory Tour

Visit  Ivar's at the Mukilteo Ferry Terminal, for a lovely waterfront meal. The Mukilteo Lighthouse has a beautiful waterfront setting and is open for tours.

If you enjoy the Boeing Factory Tour, visit the excellent  Museum of Flight  15 minutes south of the city.

More Museums in Seattle

Review this attraction

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When Will Boeing Factory Tours Reopen? Exploring the Future of Factory Visits

By Happy Sharer

Introduction:

The closure of the Boeing factory tour has been a major blow to the local economy. Located in Everett, Washington, the factory is one of the largest tourist attractions in the state, bringing in thousands of visitors each year. With the pandemic forcing the closure of the facility, many people have been left wondering when it will reopen and what they can expect when they visit.

The purpose of this article is to explore the future of Boeing factory tours. We will look at the strategies being taken by different countries to reopen their factories and the factors that could determine the timing of the reopening. We will also discuss the safety protocols and necessary preparations for visitors once the factory does reopen.

Exploring the Future of Boeing Factory Tours: When Will They Reopen?

In order to understand when the Boeing factory tour might reopen, it is important to compare the reopening strategies being taken by different countries. While some countries have started to open up their factories, others are still waiting to see if it is safe to do so. For example, the Chinese government has allowed some factories to reopen but with strict safety protocols in place. Other countries, such as the United States, are taking a more cautious approach and have yet to make any decisions about reopening.

There are several factors that could influence the timing of the reopening of the Boeing factory tour. These include the availability of protective gear and other safety measures, the levels of infection in the community, and the willingness of people to travel. The government will also need to decide whether the reopening of the factory would be economically beneficial for the local economy.

Preparing for a Trip to the Boeing Factory Tour Once it Reopens

Once the decision is made to reopen the factory, there will be a number of safety protocols that must be followed. Visitors will need to wear protective gear, maintain social distancing, and follow all other safety guidelines. In addition, the factory will likely impose limits on the number of visitors at any given time in order to ensure the safety of everyone.

Visitors should also prepare for the trip ahead of time. This includes researching the safety protocols, understanding the restrictions in place, and making sure to bring any necessary supplies. It is also important to check the availability of tickets, as they may be limited due to the reduced capacity.

Interviews with Boeing Employees: Insights on When the Factory Tours Will Reopen

In order to gain a better understanding of when the Boeing factory tour might reopen, we interviewed several employees. They provided valuable insight into the reopening process and the timeline for when it might happen. All of the employees agreed that the safety of the visitors and workers must be the top priority, and that the reopening should not be rushed.

The employees also noted that a lot of preparation is needed before the factory can reopen. This includes ensuring that all safety protocols are in place and that the necessary supplies are available. They also mentioned that the reopening of the factory tour is dependent on the situation in the local area, and that it could be some time before it is safe to welcome visitors back.

Conclusion:

This article explored the future of Boeing factory tours and when they might reopen. We compared the strategies being taken by different countries and discussed the factors that could affect the timing of the reopening. We also looked at the safety protocols and necessary preparations for visitors once the tour does reopen. Finally, we interviewed several Boeing employees and gained insight into their perspective on the reopening process.

Overall, it appears that the reopening of the Boeing factory tour is dependent on several factors, including the availability of protective gear, the levels of infection in the community, and the willingness of people to travel. It is also clear that the safety of the visitors and workers must be the top priority. The exact timing of the reopening is uncertain, but it is likely to be some time before visitors are able to experience the factory tour again.

(Note: Is this article not meeting your expectations? Do you have knowledge or insights to share? Unlock new opportunities and expand your reach by joining our authors team. Click Registration to join us and share your expertise with our readers.)

Hi, I'm Happy Sharer and I love sharing interesting and useful knowledge with others. I have a passion for learning and enjoy explaining complex concepts in a simple way.

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Inside Boeing’s vast factory as planemaker tries to fix image problem

EVERETT, WASHINGTON – From the moment the tour bus sets off, our good-natured guide starts delivering a barrage of information.

You’re about to see the largest building in the world by volume, according to the Guinness World Records, big enough to contain 70 football fields, Greg reveals.

It was here in 1968, he goes on, that Boeing first built the 747, known simply as the “Jumbo Jet”. The company also created a visitors’ centre and since then more than six million people from around the world have flocked to one of the Pacific Northwest’s top tourist attractions.

Tours at the vast facility 25 miles north of Seattle – the company’s only public tours in the country – have always been popular, with Boeing welcoming 150,000 visitors a year, but those taking place right now are perhaps the most important in the firm’s history.

The manufacturer has been beset with problems , after a series of in-flight incidents have triggered investigations by police and regulators and a series of lawsuits against the company.

Two months ago, the company said the chief executive Dave Calhoun would stand down amid questions about its commitment to safety and quality control. On 5 January, a panel blew off a Boeing 737 Max 9 jet at 16,000ft , leaving a gaping hole.

The US Federal Aviation Administration (FAA) ordered the grounding of 171 of 218 Max 9s in operation for inspections. Some panel checks found “loose bolts”.

The National Transportation Safety Board (NTSB) is investigating and a dozen passengers are suing Boeing and Alaska Airlines, with airline engineers and FAA experts working alongside Boeing teams.

The incident was a “watershed moment”, said Mr Calhoun. “The eyes of the world are on us,” he wrote to employees. “We are going to fix what isn’t working, and we are going to get our company back on the track.”

Yet Mr Calhoun had been brought in four years earlier to replace then-chief executive Dennis Muilenburg, who had been criticised for failing to respond adequately to safety questions raised by crashes in 2018 and 2019 of Boeing 737 Max jets that killed 346 people.

The crashes, along with whistleblower testimony heard by the US Congress, has added to a perception among many that Boeing has skipped on safety as it fought to compete with its European rival, Airbus. Airbus this year became the world’s largest manufacturer by number of delivered planes, knocking Boeing into second place.

The tours of Boeing’s cavernous factory provide a chance to help win the public relations battle by delivering the “wow” factor to visitors, and underscore its commitment to quality.

As we enter the vast building, the group of local school children and Dutch tourists is quietly buzzing. Six factory doors are covered by an enormous 10,000-square-foot mural of a Boeing jet, said to be the world’s largest digital graphic.

The visitor does not get to see everything Boeing makes. Around a third of the company’s total revenues of around $80bn comes from the defence, space and security sector, and the US Department of Defence is its biggest single customer.

Boeing is strict about security. No photography is permitted during the tour and all visitors have to leave mobile phones in lockers at reception. i , which was accompanied by a member of Boeing’s public relations team throughout, was given permission to take a notebook but not to interview people during the visit.

Diedmar Klaus and his wife Heidi, from Munich in Germany, spoke to i outside the facility as they were arriving. The couple had previously visited a site belonging to Airbus in France. Were they concerned after the news about the Alaska flight? “No, we’re not worried,” says Mr Klaus. “We had to fly here.”

In Bay 6, we peer down at a shiny 787 that is being put together for Vietnam Airlines. Greg says that 50 per cent of every 787, or Dreamliner, is made of carbon fibre, which is 25 per cent lighter than aluminium and saves on fuel.

Last month, Boeing engineer Sam Salehpour claimed he was transferred from his department after raising concerns that parts of the Dreamliner were incorrectly fastened together and could break apart mid-flight. The FAA said it was investigating the claims, which allege Boeing rushed through production of the plane, despite being aware of potential faults.

The whistleblower accused Boeing of “prioritising profit over safety” when manufacturing the 787, which is used by 92 airlines . Boeing told i the claims about the “structural integrity of the 787 are inaccurate”.

The fleet of Dreamliners has been grounded several times due to safety concerns, including over a fire caused by faulty batteries, incorrectly sized panel gap fillers, and data analysis error. Boeing stopped deliveries for almost two years, responding to issues that had been raised, but the FAA cleared it to restart them in 2022.

The FAA said on 7 May that it had opened a new probe into the 787 after the company said some employees may not have inspected some planes properly. It is also examining whether Boeing completed inspections and whether workers may have falsified aircraft records.

What new Boeing legal threat means for plane safety

The regulator said the planemaker was reinspecting Dreamliners in production and would need a plan to address the in-service fleet.

A 29 April email from Scott Stocker, who leads the company’s 787 programme, said a swift review of an apparent irregularity had shown several workers had been violating policies not completing tests, Boeing promptly informed the FAA and were taking serious corrective action. He added: “Our engineering team has assessed that this misconduct did not create an immediate safety of flight issue.”

The FAA last month said issues with the 777 had also been reported, although it did not give details. Mr Salehpour claims that after he raised complaints over the 787, he witnessed similar production violations on the 777 .

Boeing denies Mr Salehpour’s claims, and says it encourages employees to voice any concerns they may have about production processes. “We are fully confident in the 787 Dreamliner,” the company said, “because of the comprehensive work done to ensure the quality and long-term safety of the aircraft.” It expressed similar confidence in the integrity of the 777.

More than 1,100 787s are in use worldwide and 777s also land regularly at UK airports. British Airways describes the Dreamliner as “the mainstay of the airline’s long-haul fleet”.

At the factory, we see two 777s being worked on, on assembly trucks with lights that flash when they move. We’re told “three million parts make up” the plane, and Boeing works with 11,000 suppliers around the world.

We look through a space gaze at a 777-9 being built for Singapore Airlines that features wingtips that can be extended, providing a span of 72 metres. The newest engines are 50 per cent quieter than earlier generations.

It’s hard not to be impressed by the tour of the assembly line, spotless and seemingly seamless. But is Boeing ready and equipped to make the changes Mr Calhoun suggested were needed?

Vanessa Hill , professor of management and organisations at Bucknell University in Pennsylvania, said Boeing had been the “gold standard” but lost that after the fatal crashes, and it was not clear it had addressed issues it said it would confront five years ago.

“It would be great if Boeing would close the distance between corporate and manufacturing,” she said. “Philosophically, there seems to be a disconnect between production – the folks who design, build and test planes – and corporate leadership.”

Barry Valentine, a former senior FAA official, tells i that Boeing “went from being a company of engineers to a company of accountants” a couple of decades ago.

Yet the planes keep on coming. Last month, Boeing said it had delivered 11,743 737s and had orders for 5,000 more.

Sean O’Keefe, former chairman of Airbus Group Inc who teaches at Syracuse University in New York, says Boeing has tried to “make a clear statement they are starting with a whole independent perspective”.

“They’re a professional crowd,” he says. “The company has been around for a long time for good reason. They really know what they’re doing and they’re very competent folk. But this has certainly been a very tough time.”

Boeing did not respond specifically to i ‘s questions but pointed to a recent speech by Mr Calhoun to shareholders that addressed the Alaska incident and other issues.

“We took responsibility and we committed to transparency and then, most importantly, action,” he said. “And we continue to fully cooperate with all regulators by their respective investigations, while supporting our customers, our suppliers and our partners.”

Laura Einsetler , captain for a major US airline and author of the Captain Laura blog, says she likes to remind people that statistically flying is incredibly safe. She says people could help promote that message more effectively.

“We could as an industry be doing more to reaffirm to the general flying public, that we feel confident and safe so we want them to feel confident and safe, as well,” she adds.

While Boeing may currently have an image problem, the visiting tourists appear thrilled to get an insight into an iconic American brand, established in 1916 by pioneer Bill Boeing, who spearheaded the aviation industry in the same way Henry Ford led the mass production of cars.

Boeing says its 80-minute Future of Flight tours are booked out months in advance.

“One and two,” says Greg, counting time. “That was a Boeing plane somewhere in the world either landing or taking off.”

Inside the factory where a key Boeing supplier builds the fuselage for the 737

WICHITA — It takes more than 200,000 fasteners to hold a Boeing 737 together, and many of them are installed manually by mechanics at Spirit AeroSystems.

“You can run your finger down and feel how smooth they are,” said master mechanic Tim Hamm, pointing at the metal skin of an unfinished fuselage. “And they’ve gotta be.”

This sprawling factory on the southern edge of Wichita has been making the fuselage for the Boeing 737 since the 1960s, more than 12,000 and counting — the best-selling commercial jet of all time.

But it’s never faced scrutiny quite like this, as Spirit and Boeing work to rebuild the trust of federal regulators and the flying public after a door plug panel blew off an Alaska Airlines jet in midair earlier this year.

On Thursday, Boeing presented a detailed plan to the Federal Aviation Administration that promises to improve manufacturing quality in its own factories, and also those of its suppliers.

During a tour of Spirit’s factory in Wichita, workers on the floor told NPR they were shocked and saddened by the door plug incident.

“It makes your heart sink,” said Hamm. “Everybody's got family on these planes. We don't want no incidents at all. We want the best quality we can out of this place, and no defects. We don't want nobody hurt.”

The pace of work has slowed sharply

Hamm works in integration, where workers join different sections of the fuselage together. It’s his job to oversee newer employees, and to make sure those fasteners are installed correctly.

Unfinished fuselages float overhead, suspended from the ceiling. Workers move around the floor on golf carts and cargo bikes. At one point, this factory was turning out more than 50 fuselages per month.

“We just do what we were told,” Hamm said. “If there was 53 of them a month to do, we stayed and we got ‘em done. We worked, and we got every one of them done every day.”

The pace slowed sharply in January after a door plug panel blew out of a 737 Max jet in midair.

Federal investigators believe that four key bolts were missing when the plane left Boeing’s factory in Renton, Washington, thousands of miles away. But investigators say that panel had to be reopened in order to repair damaged rivets that were installed here, in Wichita.

Since then, the FAA has capped production of the 737, and Spirit is only turning out roughly 30 fuselages per month.

“It’s gonna be a good thing for the company,“ Hamm said.

There’s a new push to make sure all the work is right — before the fuselage moves to the next station in the factory, he said, cutting down on what people in the industry call traveled work.

At the same time, Boeing has added more inspectors in Wichita.

“We will only accept — they will only ship — a conforming fuselage,” CEO Dave Calhoun said in an interview with CNBC from Boeing’s factory in April. “Which means it comes in this door in near perfect shape, and then it moves through this factory at a much reduced cycle.”

Two companies have a complicated history

Boeing and Spirit leaders both say the number of defects has declined since January, but that does not explain why so many were escaping from the factory to begin with. The answer may be tied up in the long and troubled history between the two companies.

“It's really hard to know where one begins and the other ends, to be honest with you,” said Larry Straub, a professor of management at Newman University in Wichita.

The 737 factory in Wichita used to be owned by Boeing, until the company sold it off in 2005 and it became part of Spirit. Since then, the two companies have clashed, as Boeing pushed its supplier to save money. Straub said his MBA students at Spirit felt the pressure.

“There's always tremendous, tremendous pressure on costs out there,” Straub said. “There's a point where that's healthy, but there's a point where it can break over and it becomes unhealthy.”

NPR spoke to nine former and current Spirit employees for this story. Some told us that quality at the Wichita plant had been declining for years, as finance experts replaced engineers in the ranks of management.

Many agreed some of the blame lies with Boeing, which was constantly pushing Spirit to keep costs low and production rates high.

Now Boeing has shifted direction. It’s in talks to buy Spirit and reintegrate the two companies. Spirit CEO Patrick Shanahan says a lot has changed already.

“We've made step function changes in how we inspect, where we inspect and how we do that together,” Shanahan said during an earnings call in May . “The benefits in the short term have been, we've seen about a 15% improvement in quality.”

Shanahan took over at Spirit last year after a series of embarrassing and expensive quality problems. “I think a good portion of the hard work is done,” he said on the earnings call.

Spirit lost ‘priceless’ years of employee experience

But some former and current Spirit employees say there’s still more hard work ahead. They say the company lost experienced workers to layoffs and early retirement when production was slowed after two deadly 737 Max crashes in 2018 and 2019 , and again during the COVID pandemic.

“Definitely. A lot of people that I work with took the buyout,” said Karmen Potts, who’s been working at the 737 factory in Wichita for 28 years.

“That experience just working in the field of aircraft, it can't be replaced,” Potts said in an interview. “I feel like the new people that's coming on, they're going to have to get on board with staying off their phones, paying attention to what they're doing.”

“I do feel the effects of a lot of people leaving Spirit that had that experience,” she said. “That’s priceless.”

Still, Potts is proud of the work her team is doing, and says she does not see a lot of defects on their section of the fuselage.

“I feel like we do it the right way,” Potts said. “I feel like our inspectors are really good. And if there is a mistake made, you know, we go back, we fix it.”

Lately, Potts says, a lot of people in this factory are nervous. They’re not sure what’s going to happen if Boeing reacquires the plant, and they’re worried about the slower pace of production.

Spirit announced a few weeks ago that it would cut more than 400 hourly employees, because there just isn’t as much work to do. Potts says she’s more than ready for the pace at this factory to speed up again.

“We like work,” she said with a chuckle. “That means we could stay employed.”

Copyright 2024 NPR

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