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A Boeing whistleblower has claimed that the passengers could be left on the 787 Dreamliner, to suffer without oxygen, if The Cabin were a sudden decompression.

John Barnett says tests suggest up to a quarter of the oxygen systems could be faulty and could not work, if needed.

He also claimed that faulty parts were deliberately built-in to the levels on the Production Line at a Boeing factory.

Boeing denies his allegations and says that all its aircraft to the highest levels of safety and quality.

The Company , under intensive control in The Wake of two catastrophic accidents, the other one of its planes the 737 Max - the Ethiopian Airlines crash in March, and Lion Air disaster in Indonesia in the past year.

Mr Barnett, a former Quality Control engineer, worked for Boeing for 32 years until his retirement for health reasons in March 2017.

From 2010 onwards, he worked as a quality manager at the Boeing plant in North Charleston , South Carolina .

John Barnett is a former Quality Control manager at Boeing , This plant is one of two that are involved in the construction of the 787 Dreamliner, a state-of-the-art modern airliner routes generally on long routes around The World . after its entry into service the aircraft proved to be a hit with airlines, and a useful source of income for The Company .

meant, But according to Mr. Barnett, 57, of the hurry, with the new aircraft from the production that The Assembly was fast and security was compromised. The Company denies this and insists that "safety, quality and integrity are at The Core of the Boeing values".

In 2016, he says of the BBC, he exposed problems with emergency oxygen systems. These are the passengers and the crew to keep them alive, if The Cabin pressurization for a certain reason not in height. Respiratory protection masks are designed to drop down from the ceiling, then the supply of oxygen from a gas cylinder.

Without such systems, the occupants of an aircraft would be incapacitated quickly. At 35,000 ft (10,600 m), you would be unconscious in less than a minute. At 40,000 ft, it could happen within 20 seconds. Brain could follow damage and even death.

Although the sudden decompression events are rare, they happen. In April 2018, for example, a hit by the debris from the damaged Engine . A passenger sitting next to The Window suffered severe injuries and later died as a result of drawing But others were in the location of The Emergency oxygen supplies, and survived unharmed.

A window blew out of this Southwest Airlines plane after being hit by debris from a damaged Motor resulting in a loss of Cabin Pressure , Mr Barnett says that if the shutdown systems, which had suffered minor cosmetic damage, he found that some of the oxygen bottles were not discharged, if you were meant to have. In the time that he had to be a controlled test performed by Boeing 's own research and development Department.

with This test, the used, oxygen-systems that were "straight out of stock" and undamaged, was designed to mimic the way in which it will be delivered on Board of an aircraft, with exactly the same electrical current as the trigger. He says 300 systems were Tested , and 75 of them are not implemented properly, a failure rate of 25%.

Mr Barnett says his attempts to get the thing looked at, were blocked by the Boeing Manager. In the year 2017, he complained to the US regulator, the FAA, and that no measures were taken to solve the problem. The FAA, however, said it could not substantiate that claim, because Boeing had indicated that it was the topic at the time.

Boeing itself rejects Mr Barnett claims.

It does admit that in the year 2017 there "were some oxygen bottles received from suppliers that were not providing properly. We removed the bottles from the production, so no broken bottles were on the planes, and we treated The Matter with our suppliers".

Boeing 's Dreamliner made its first flight in 2009, and about 800 are in service with airlines from all over The World , But it also shows that "each passenger oxygen system installed on our aircraft will be Tested several times to ensure prior to delivery that it works properly, and must pass these tests in order to stay on the plane. "

"The System is also Tested regularly, as soon as the plane enters service," it says.

This is not the only criticism to be leveled at Boeing in regard to the South Carolina plant, But . Mr Barnett also says that Boeing will not follow its own procedures for the tracking of parts through The Assembly process, whereby A Number of defective items "lost".

He claims that under pressure, the workers are also sub-standard parts from the scrap bins equipped aircraft on the line, in at least one case, with the knowledge of a senior manager. He says that this was done in order to save time, because "Boeing South Carolina is strictly plan and cost driven by time".

in The Matter of the parts, the lost, the beginning of 2017, a review by the Federal Aviation Administration confirmed to Mr Barnett's concerns, to determine that the location of a minimum of 53 "non-conforming" parts unknown, and that they lost. Boeing was ordered to take counter-measures.

Since then, The Company says it is "firmly of the FAA determination, the findings with respect to the tracking of parts and implemented corrective actions to prevent recurrence". It has no further comment on the possibility of non-compliant parts so that it is on the completed aircraft, although an Insider at the North Charleston plant, it could not happen.

2017 is a review by the Federal Aviation Administration ordered Boeing to take counter-measures, Mr Barnett is currently in legal action against Boeing , which he accused of defamation of his character and hinder his career because of the issues he pointed out, ultimately, to his retirement. The Company , the answer is that he will go a long existing plans into pension, and this they did voluntarily. It is called "Boeing has not in any way a negative Mr Barnett affects the ability to continue, in which profession he wishes".

The Company says it offers a concern to its employees a variety of channels for the and complaints, and has strict processes in place to protect you and make sure that the problems that you considered carefully. He says: "We demand and expect our employees to voice concerns and when they do, we examine to solve thoroughly and completely. "

But Mr Barnett is not the only Boeing employees have concerns about Boeing 's manufacturing processes. Earlier this year, for example, it turned out, to report that, according to the Ethiopian Airlines 737 Max crash, four current or former employees of FAA contacted the hotline, potential problems.

Mr Barnett believes that the concerns that he has highlighted, reflect a company culture that "all about speed, cost-cutting and bean count (jobs sold)". He claims the Manager of the "not worried about security, just schedule a meeting".

This is a view that has the support of a former engineer, Adam Dickson, who was involved with the development of the 737 Max at Boeing 's Renton factory in Washington state.

He told the BBC that there is "to keep a drive, the plane moves through the factory. Often there was pressure to keep up production levels.

"My team fought constantly, the factory, the processes and the quality. And our managers were no help. "

In October, the democratic Congressman Albio Sires asked Boeing CEO Dennis Muilenburg and production pressure with the 737 Max In congressional hearings in October

In it, the manager complained about the workers as "exhausted" from working in a very high pace over a longer period of time.

He said the schedule of the printing was "The Creation of a culture where the employees are to be avoided, either consciously or unconsciously, established processes", has a negative impact on quality.

For the First Time in his life, the E-Mail, the author said he was skeptical that His Family aboard a Boeing aircraft.

Boeing says that together with the FAA, it implemented a "rigorous audit" process to ensure its aircraft are safe, and that all of them are going through "A Number of safety-and test-flights", as well as extensive checks, they are allowed to leave the factory.

Boeing recently an independent review of its security processes, the it says "found rigorous enforcement of, and compliance with mandated both by the FAA aircraft certification standards and Boeing aircraft, design and engineering requirements. "He said that the review "found that the design and development of the [737] Max was in accordance with the procedures and processes that consistently produces safe aircraft. "

Boeing in North Charleston factory in South Carolina is one of the two parties involved in the construction of the 787 Dreamliner, Mr Barnett, meanwhile, is deeply concerned about the safety of the aircraft, to build the he has helped.

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Source of news: bbc.com