Troubled aircraft manufacturer Boeing is investigating another quality issue with its aircraft after finding hundreds of incorrectly installed fasteners on the fuselage of undelivered 787 Dreamliners. 

The US company confirmed reports from Reuters that it was checking fasteners on some of its jets following the discovery, but added that planes already in-service could continue to operate as normal. 

The error adds to the growing list of issues found with Boeing’s production lines in 2024, which saw the Federal Aviation Administration (FAA) step in to oversee the its 737 MAX factory.

The regulator has also been limiting production of the model after a series of incidents and damning reports beginning with the door plug blow out of an Alaska Airlines 737 MAX 8 in January. 

While previous issues have mainly stemmed from the 737 MAX line in Renton, Washington, the incorrectly fitted fasteners were discovered at Boeing’s South Carolina factory where the 787 exteriors are fitted to skeletal supports on the fuselage.

The safety of the 787 production line had already been called into question by Boeing whistleblower Sam Salehpour who told the US Congress that parts of the aircraft were not being properly joined in a hearing earlier this year, claims which the company had disputed.

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The FAA confirmed that the latest issue had been disclosed by Boeing and said it was working closely with the company to “determine appropriate actions” and ensure an immediate fix to production. 

According to inside sources, the error may have seen fasteners torqued from the wrong side at more than 900 points per plane, though Boeing will reportedly decide how much rework may need to be done following its investigation into the issue. 

The issue will be a particular thorn in the side of Boeing as it comes only weeks after the FAA confirmed it would be keeping a production cap on the manufacturer’s output after reviewing its new safety roadmap. 

FAA Administrator Mike Whitaker, who toured Boeing’s South Carolina plant on Friday in a pre-planned visit, previously said his organisation wanted to “set a new standard of safety” at the company.