18 Sep 2023
Door plug opened at Boeing factory
According to the NTSB, workers at Boeing's Renton, Washington, factory opened the left mid exit door plug for rivet rework without the required documentation.
Incident
How the Alaska Airlines 1282 door plug separation unfolded
On January 5, 2024, the left mid exit door plug separated from an Alaska Airlines Boeing 737-9 climbing out of Portland, Oregon, and the airplane returned and landed safely. The NTSB determined that bolts meant to hold the plug in place were missing after factory rework at Boeing and cited Boeing training and oversight and FAA surveillance. The FAA grounded affected 737-9 airplanes, capped 737 MAX production and later proposed civil penalties against Boeing.
5 January 2024 to today · 27 dated events · 11 sources
people on board177171 passengers and 6 crew, no fatalities
minor injuries81 flight attendant and 7 passengers
altitude at separation14,830 ftper NTSB
FAA civil penalties$3.1 million$3,139,319 proposed September 2025, reported paid January 2026
Overview · 5 Jan 2024 to Jan 2026 · click a dot to jump
2023
19 Sep 2023
Plug closed without retaining bolts
The NTSB said the plug was closed the next day and, because the work was not documented, no quality assurance inspection of the closure took place. Its preliminary report described a Boeing photo sent around 1839 that day showing the plug closed with no retaining bolts in three visible locations.
2024
5 Jan 202417:07 PST
Flight 1282 departs Portland
The NTSB said the Boeing 737-9 operating as Alaska Airlines flight 1282 departed Portland International Airport about 1707, with a planned destination of Ontario, California.
5 Jan 202417:12 PST
Turning point
Left mid exit door plug separates
At 1712:33 the airplane was climbing through about 14,830 ft when the cabin pressure dropped and the cabin altitude warning activated, according to the NTSB. The master caution alert followed one second later.
5 Jan 202417:13 PST
Airplane reaches maximum altitude
The NTSB said the airplane reached its maximum altitude of 16,320 ft at 1713:41. The report says the captain asked the first officer to declare an emergency but gives no time for it.
5 Jan 202417:13 PST
Crew selects descent to 10,000 ft
At 1713:56 the selected altitude changed from 23,000 ft to 10,000 ft, the NTSB report states.
5 Jan 202417:17 PST
Airplane descends below 10,000 ft
The NTSB said the airplane descended below 10,000 ft at 1717:00.
5 Jan 202417:18 PST
Cabin altitude warning stops
The cabin altitude warning for more than 10,000 ft deactivated at 1718:05, according to the NTSB report.
5 Jan 202417:26 PST
Flight lands back in Portland
The flight landed at 1726:46, about 14 minutes after the plug separated, the NTSB said. Of the 177 people on board, one flight attendant and seven passengers had minor injuries.
6 Jan 2024
Turning point
FAA grounds certain 737-9 MAX airplanes
The FAA issued an emergency airworthiness directive grounding certain 737-9 MAX airplanes operated by US airlines or in US territory until they were inspected. The agency said the order affected approximately 171 airplanes worldwide.
8 Jan 2024
FAA approves inspection method
The FAA approved a method of compliance and said airplanes would stay grounded until operators completed enhanced inspections of both door plugs, their components and fasteners.
11 Jan 2024
FAA opens investigation into Boeing
The FAA formally notified Boeing that it was investigating whether the company ensured completed products conformed to their approved design and were safe to operate.
17 Jan 2024
FAA widens probe to manufacturing lines
In a January 17 update, the FAA said it had announced inspection and maintenance requirements as a step before any return to service and was investigating Boeing's manufacturing practices and production lines, including those of subcontractor Spirit AeroSystems.
Jan 2024
FAA halts 737 MAX production expansion
The FAA said it halted production expansion of the 737 MAX. Press reports later described the limit as a cap of 38 airplanes a month.
28 Feb 2024
FAA orders a comprehensive action plan
After a meeting with Boeing leadership, the FAA required Boeing to deliver a comprehensive action plan within 90 days covering audit results, expert panel findings and its safety and quality management systems.
4 Mar 2024
FAA releases audit findings
The FAA said its six week audit of Boeing and Spirit AeroSystems identified non-compliance issues in manufacturing process control, parts handling and storage, and product control.
12 Mar 2024
NTSB schedules investigative hearing
The NTSB announced an investigative hearing on the door plug separation for August 6 and 7, 2024.
25 Mar 2024
Boeing announces leadership changes
Boeing said CEO Dave Calhoun would step down at the end of 2024, Commercial Airplanes chief Stan Deal would retire, and Steve Mollenkopf would succeed Larry Kellner as board chair.
May 2024
Boeing submits corrective action plan
The FAA said it received Boeing's corrective action plan, which included strengthening its safety management system and employee safety reporting, simplifying processes and work instructions, and increasing internal audits.
27 Jun 2024
NTSB sanctions Boeing over media briefing
The NTSB said a Boeing executive shared non-public investigative information at a media briefing. It removed Boeing's access to investigative information and said it would subpoena Boeing to the hearing.
6 Aug 2024
Two day NTSB hearing opens
The NTSB held its investigative hearing on the flight 1282 investigation in Washington on August 6 and 7, 2024.
5 Dec 2024
FAA chief reviews Boeing progress
The FAA said Administrator Whitaker visited the Renton factory that week and met senior Boeing leaders including CEO Kelly Ortberg. He said Boeing had made progress on its plan and that the FAA would keep monitoring as production ramped up.
2025
24 Jun 2025
Turning point
NTSB determines probable cause
The NTSB determined that the separation resulted from Boeing's inadequate training, guidance and oversight of its parts removal process, with ineffective FAA enforcement as a contributing factor. It found the four bolts were missing before the flight and the plug had moved upward over earlier flights.
“This time, it was missing bolts securing the MED plug.”Jennifer Homendy, NTSB Chair, National Transportation Safety Board
12 Sep 2025
FAA proposes $3.1 million in penalties
The FAA proposed $3,139,319 in civil penalties against Boeing for violations from September 2023 through February 2024, including actions related to the door plug blowout and a Boeing employee pressuring an ODA unit member to sign off on an airplane. Boeing had 30 days to respond.
17 Oct 2025
FAA allows higher 737 MAX output
Flying magazine reported that the FAA allowed Boeing to raise 737 MAX production from 38 to 42 airplanes a month, ending the cap set in January 2024.
8 Dec 2025
Boeing completes Spirit AeroSystems purchase
Boeing announced it had completed its acquisition of fuselage supplier Spirit AeroSystems.
“our focus is on maintaining stability so we can continue delivering high quality airplanes”Kelly Ortberg, Boeing president and CEO, Boeing
2026
Jan 2026
Boeing pays the FAA penalty
Reuters reported in September 2026 that Boeing paid the full $3.1 million civil penalty in January 2026, a payment that had not been publicly disclosed, according to AVweb's account of that report.
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Sources
11 records, ranked by type- 1Official record24 Jun 2025Investigation DCA24MA063: Alaska Airlines flight 1282National Transportation Safety Board · ntsb.gov
- 2Official record24 Jun 2025Aircraft Accident Report AIR-25-04: In-Flight Separation of Left Mid Exit Door Plug, Alaska Airlines Flight 1282National Transportation Safety Board · ntsb.gov
- 3Official record24 Jun 2025Boeing's Inadequate Training, Guidance and Oversight Led to Mid-Exit Door Plug Blowout on Passenger JetNational Transportation Safety Board · ntsb.gov
- 4Official recordFeb 2024Aviation Investigation Preliminary Report DCA24MA063National Transportation Safety Board · ntsb.gov
- 5Official record27 Jun 2024Boeing Sanctioned for Sharing Non-Public Investigative Information With Media on 737 Max 9 Door Plug InvestigationNational Transportation Safety Board · ntsb.gov
- 6Official record5 Dec 2024Updates on Grounding of Boeing 737-9 MAX AircraftFederal Aviation Administration · faa.gov
- 7Official record12 Sep 2025FAA Proposes $3.1 Million in Fines Against BoeingFederal Aviation Administration · faa.gov
- 8Subject's own statement25 Mar 2024Boeing Announces Board and Management ChangesBoeing · boeing.mediaroom.com
- 9Subject's own statement8 Dec 2025Boeing Completes Acquisition of Spirit AeroSystemsBoeing · boeing.mediaroom.com
- 10News report20 Oct 2025Boeing Allowed to Increase 737 Max ProductionFlying Magazine · flyingmag.com
- 11News report3 Sep 2026Boeing's $3.1 Million FAA Fine Payment Went UndisclosedAVweb, citing Reuters · avweb.com
Last updated 31 October 2026. Spotted an error? See corrections. Every event links to the record it comes from. Allegations are attributed to whoever made them.