FAA warned about boeing 787 dreamliner back in 2018

The Air India flight that crashed in Ahmedabad, India, on June 12, killing all 232 passengers and 12 crew members en route to London, was a Boeing 787 Dreamliner. While this is the first instance of a crash involving this specific model, the U.S. Federal Aviation Administration (FAA) had already issued a warning in 2018 regarding the entire Boeing 787 Dreamliner series.

In its bulletin, the FAA highlighted a potential issue with the fuel control switches used in both Boeing 737 and 787 models, warning that the locking feature on these switches could be inactive. Although the issue wasn’t classified as an “unsafe condition” at the time, the catastrophic crash in Ahmedabad in 2025 has now underscored how even a minor mechanical flaw can lead to disastrous consequences.

The Air India flight crashed just minutes after takeoff, killing 260 people. Investigations revealed that both of the aircraft’s engines suddenly shut down within seconds of each other. Cockpit voice recordings captured the pilots questioning each other in confusion, unsure why the fuel switches had turned off. The locking mechanism on the fuel control switches is designed specifically to prevent such accidental shutdowns. Normally, a pilot must lift and rotate the switch to operate it—this is a basic safety standard. However, if the locking feature is inactive, even slight turbulence can cause the switch to turn unintentionally, shutting off the engines mid-flight and turning an aircraft into wreckage within moments.

Although the FAA’s 2018 bulletin raised concerns about inactive locking features in the switches on Boeing 737 and 787 models, it stopped short of declaring the issue unsafe, and therefore no mandatory inspections were ordered. But following the Ahmedabad crash, the issue has triggered widespread alarm across the aviation industry.

India’s Directorate General of Civil Aviation (DGCA) has since ordered Air India to inspect all fuel control switches on its Dreamliner fleet, setting a deadline of July 21 for the inspections to be completed. Major global airlines including Etihad, Singapore Airlines, and British Airways are also inspecting the fuel control switches on their Boeing fleets.

The Aircraft Accident Investigation Bureau (AAIB) is leading the investigation into the Ahmedabad crash. In a 15-page preliminary report, the bureau confirmed that both engines lost fuel supply within seconds of takeoff. The cockpit transcript reveals one pilot asking the other, “Why did you shut off the fuel?” and the other replying, “I didn’t.”

Experts say such automatic engine shutdowns are highly unusual. The fuel control switch is equipped with a locking mechanism precisely to prevent accidental activation. They stress that every Dreamliner in operation worldwide should undergo inspection of this component.

Biman Bangladesh Airlines currently operates six Boeing Dreamliners—Akashbeena, Gangchil, Sonar Tori, Hangsabalaka, Rajhansa, and Achin Pakhi. According to Biman’s Managing Director Dr. Shafiqul Rahman, technical inspections have already been conducted on these aircraft, and no issues were found. “If Boeing issues further instructions, we will comply accordingly,” he added.

However, Biman Bangladesh’s past experience with Boeing has not been entirely positive. One Dreamliner developed a cracked windshield just four years into service, and a Boeing 777 model remained grounded in Italy for an extended period, causing dissatisfaction within the airline. Aviation expert Kazi Wahidul Alam has described these incidents as “unusual and suspicious.”

Frustrated with Boeing’s poor after-sales support, Biman Bangladesh is now leaning toward Airbus. Sources have confirmed that Airbus representatives have already held meetings at Biman’s headquarters to discuss potential collaboration.