DGCA Orders Safety Checks of Air India’s Boeing 787 Fleet After Ahmedabad Crash Kills 241

New Delhi, 13th June 2025: A day after the tragic plane crash in Ahmedabad claimed 241 lives, the Directorate General of Civil Aviation (DGCA) has ordered mandatory safety checks on Air India’s Boeing 787 Dreamliner fleet. Effective from June 15, the checks will be carried out on all Boeing 787-8 and 787-9 aircraft with GenX engines before every flight. The reports of each check must be submitted to the DGCA.

Tata Group-owned Air India currently operates 26 Boeing 787-8 and 7 Boeing 787-9 aircraft. The DGCA directive mandates additional maintenance procedures as part of the enhanced safety protocol.

These 9 Checks are Now Mandatory Before Every Flight:

1. Fuel system check – Ensuring all fuel-related parameters are within safe limits.
2. Cabin air system check – Verifying proper functioning of the air supply system.
3. Engine control check – Ensuring all engine systems operate normally.
4. Engine fuel and oil system check.
5. Hydraulic system check – Particularly the systems controlling wheels and brakes.
6. Take-off data review – Re-examining speed, weight, and other take-off metrics.
7. Flight control check – Conducted at every stopover.
8. Engine power test – Mandatory within the next two weeks.
9. Repeated fault review – No maintenance to be closed until issues seen in the last 15 days are resolved.

About the Boeing 787-8 Dreamliner

The 787-8 is a mid-sized, long-haul, twin-engine wide-body jet designed to be fuel-efficient and comfortable. It replaces the older Boeing 767 series.

Key Features:

• Lightweight composite materials: 50% of the body made of carbon fiber.
• Largest windows: 27×47 cm, more natural light.
• High cabin pressure: Equivalent to 1,900 meters altitude for better oxygen and less fatigue.
• Mood lighting: LED lights reduce jet lag.
• Quieter cabins and roomier overhead bins.

Past Controversies Involving the Boeing 787-8:

1. Battery Fires (2013)

Two Dreamliners caught fire due to lithium-ion battery issues, leading to a global grounding of all 787s for three months. Boeing redesigned the battery system after FAA intervention.

2. Body Joint Gaps (2020–2022)

Manufacturing defects were found in the fuselage assembly, resulting in paused deliveries and FAA oversight. Boeing later admitted to quality lapses.

3. Structural Risks (2024)

Whistleblower engineer Sam Saleh claimed that parts were improperly joined, risking in-flight breakage. Boeing initially acknowledged manufacturing changes but later denied safety concerns.

4. Technical Glitches

Reports of engine failures, oil leaks, cracked windshields, fuel system flaws, and software issues plagued the aircraft. In 2024, an ANA flight in Japan had to abort take-off due to hydraulic oil leakage.

Industry Impact

The Ahmedabad crash has intensified global scrutiny of Boeing’s Dreamliner program. While the cause of the crash is under investigation, the DGCA’s proactive checks reflect growing concerns about the aircraft’s safety record and Boeing’s quality control.

Passenger Advisory

Travellers flying Air India’s long-haul international routes should expect possible delays or schedule adjustments as inspections and maintenance are carried out across the 787 fleet.