A recent report has highlighted significant issues with Boeing's workforce involved in rocket production. The report, issued by NASA's inspector general, points out that Boeing's quality control practices at the Michoud Assembly Facility in Louisiana are lacking. This is largely due to the workforce having insufficient aerospace production experience.
The lack of a qualified workforce has led to numerous "Corrective Action Requests" and has caused delays and increased costs for the Space Launch System (SLS) rocket program. For instance, unsatisfactory welding operations resulted in propellant tanks that did not meet specifications, causing a seven-month delay.
These findings are concerning, especially given the importance of the SLS rocket for NASA's Artemis program, which aims to return humans to the Moon.
The Space Launch System (SLS) is NASA's super heavy-lift launch vehicle designed for deep space exploration. It is a key component of NASA's Artemis program, which aims to return humans to the Moon and eventually send astronauts to Mars.
The audit was performed, by the NASA Inspector General, because the SLS’s new upper stage — the Exploration Upper Stage (EUS)— is a critical component of the SLS upgrade, which is being done by the Boeing Company.
Once completed, the EUS will give the SLS a 40% upgrade in capability to send the Orion Multi-Purpose Crew Vehicle capsule and large cargos to the Moon, from 27 metric tons under Block 1—the SLS rocket’s first iteration—to 38 metric tons with Block 1B.
According to Safety and Mission Assurance officials at NASA and DCMA officials at Michoud, Boeing’s quality control issues are largely caused by its workforce having insufficient aerospace production experience," the report states. "The lack of a trained and qualified workforce increases the risk that the contractor will continue to manufacture parts and components that do not adhere to NASA requirements and industry standards."
This lack of a qualified workforce has resulted in significant program delays and increased costs. According to the new report, "unsatisfactory" welding operations resulted in propellant tanks that did not meet specifications, which directly led to a seven-month delay in the program.
Notably, SLS is the only rocket capable of sending the Orion spacecraft, astronauts, and large cargo directly to the Moon in a single mission. The rocket has multiple configurations, with the initial Block 1 capable of lifting 95 metric tons to low Earth orbit (LEO) and future versions (Block 1B and Block 2) designed to carry even heavier payloads.
The SLS will support various missions, including crewed lunar landings, deep space exploration, and potentially missions to Mars.
The SLS represents a significant advancement in space exploration technology, combining power, versatility, and the capability to support long-duration missions beyond Earth's orbit.
NASA Inspector general's report has projected that SLS Block 1B costs will reach approximately $5.7 billion before the system is scheduled to launch in 2028. This is $700 million more than NASA’s 2023 Agency Baseline Commitment, which established a cost and schedule baseline at nearly $5 billion.
EUS development accounts for more than half of this cost, which the report estimates will increase from an initial cost of $962 million in 2017 to nearly $2.8 billion through 2028. Boeing’s delivery of the EUS to NASA has also been delayed from February 2021 to April 2027, and when combined with other factors, suggests the September 2028 Artemis IV launch date could be delayed as well.
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