The recent crash of an Air India Boeing 787-8 Dreamliner, which resulted in 241 fatalities out of 242 passengers, has drawn renewed attention to long-standing safety concerns involving the aircraft’s manufacturer, Boeing.
The incident marks the first deadly crash involving a Boeing 787 since its debut in 2009 and brings the legacy of whistleblower John Barnett back into the spotlight.
The ill-fated Air India Flight 171 was operating a scheduled route from Ahmedabad to London Gatwick when it went down shortly after takeoff. The tragedy has reopened scrutiny of Boeing’s production practices—particularly those exposed by former quality manager John Barnett, who spent years raising concerns over safety flaws in the 787 Dreamliner programme.
Barnett joined Boeing in 1988 and built a career as a quality inspector. By 2010, he was stationed at Boeing’s North Charleston facility in South Carolina—the site responsible for assembling the 787 Dreamliner.
Between 2010 and 2017, Barnett raised alarm bells about declining safety standards at the Charleston plant. He claimed workers were being pressured to overlook defects to keep up with production deadlines. Among his most serious allegations were the presence of metal shavings near critical wiring—posing a risk of electrical failures mid-flight—and concerns that roughly 25% of oxygen masks might malfunction in emergencies. He also accused the company of poor tracking of parts and failing to properly document installations.
These concerns were formally submitted to the Federal Aviation Administration (FAA) and the Occupational Safety and Health Administration (OSHA) in 2017. While the FAA confirmed some of the issues and required Boeing to make corrections, OSHA ultimately sided with the company in 2021. Barnett, who had by then retired due to health reasons, appealed the decision.
He also alleged that Boeing retaliated against him through professional isolation, denial of promotions, and a toxic work atmosphere.
Even after retirement, Barnett continued to voice his concerns publicly. He was featured in the 2022 Netflix documentary Downfall: The Case Against Boeing, which explored broader cultural and safety failures at the aerospace giant, particularly after the 737 MAX crashes. Following the door plug incident on an Alaska Airlines flight in early 2024, Barnett again criticised Boeing for ongoing quality control failures.
In March 2024, just before he was scheduled to testify in a whistleblower retaliation case, Barnett was found dead in his truck outside a Charleston hotel. Authorities reported a self-inflicted gunshot wound and a handgun in his right hand. A handwritten note discovered in the vehicle read: “I can’t do this any longer. F**k Boeing. I pray Boeing pays.” Forensic analysis confirmed his death as suicide.