Air India Safety Crisis: DGCA Warnings, Airbus Violations, and Boeing 787 Crash Aftermath | Latest Updates

The world of aviation is a delicate ecosystem, where precision, meticulous maintenance, and unwavering adherence to safety protocols are paramount. Any deviation can have catastrophic consequences, as tragically underscored by recent events. While the global aviation community grapples with the aftermath of the Air India AI 171 Boeing 787 crash on June 12, 2025, a separate, yet equally concerning, issue has emerged: the Directorate General of Civil Aviation (DGCA) had issued stern warnings to Air India regarding significant safety protocol violations on its Airbus fleet days before the fatal Boeing crash. This pre-existing pattern of non-compliance paints a troubling picture of systemic issues within the airline, raising critical questions about oversight, accountability, and the future of safety for India’s national carrier.

The Unrelated, Yet Alarming, Airbus Violations

It is crucial to differentiate between the tragic AI 171 crash and the DGCA’s prior warnings. The warnings issued by the DGCA to Air India were not related to the Boeing 787 incident. Instead, they focused on lapses concerning the mandatory inspection of critical emergency equipment on several of Air India’s Airbus aircraft.

During inspections conducted in May 2025, the aviation regulator discovered that three Air India Airbus aircraft were actively operating with overdue mandatory checks on their escape slides – equipment vital for emergency evacuations. These findings were not mere procedural oversights; they represented a direct contravention of standard airworthiness and safety requirements.

Specific Instances Highlighted by the DGCA Report:

• Airbus A320: An inspection for this aircraft was delayed by over a month, finally being conducted on May 15, 2025. Disturbingly, during this period of overdue inspection, AirNav Radar tracking data revealed that the aircraft continued to serve international routes, including high-traffic destinations like Dubai, Riyadh, and Jeddah. This meant that passengers on these international flights were potentially flying on an aircraft with unverified critical emergency equipment.
• Airbus A319: Used for domestic flights, this aircraft had its checks delayed by more than three months. Such a prolonged delay raises serious questions about the airline’s internal scheduling and adherence to maintenance timelines.
• A Third Aircraft: While details were less specific, another aircraft was found to have missed its inspection deadline by two days. While seemingly minor compared to the other instances, it still points to a lax attitude towards compliance.

The DGCA’s report explicitly stated, “The above cases indicate that aircraft were operated with expired or unverified emergency equipment, which is a violation of standard airworthiness and safety requirements.” The regulator further underscored the severity of Air India’s inaction, noting that the airline “failed to submit timely compliance responses” to identified deficiencies, which, in the DGCA’s view, “further evidencing weak procedural control and oversight.” This points to a deeper issue than just isolated incidents; it suggests a systemic failure in the airline’s internal quality and planning departments.

Why Emergency Escape Slides are Non-Negotiable

The importance of well-maintained and functional emergency escape slides cannot be overstated. In the event of an emergency landing or an evacuation on the ground or water, these slides are the primary means for passengers and crew to quickly and safely egress the aircraft. A malfunction in such a critical system during an accident could lead to severe injuries or even fatalities, hindering a timely evacuation and potentially trapping individuals inside a hazardous environment.

Vibhuti Singh, a former legal expert at India’s Aircraft Accident Investigation Bureau, emphasized this gravity, stating, “In case of accident, if they don’t open, it can lead to serious injuries.” The DGCA’s stance is equally unequivocal: aircraft failing to undergo mandatory inspections would have their airworthiness certificates considered suspended. This is a powerful regulatory tool, designed to ground aircraft that do not meet safety standards.

Air India’s Response and the Broader Context

In response to the DGCA’s warnings, Air India, which was acquired by the Tata Group from the government in 2022, issued a statement acknowledging the concerns. The airline stated it was “accelerating” the verification of all maintenance records, including escape slide dates, with completion expected within days. They also clarified that in one instance, the issue was discovered when an AI Engineering Services engineer “accidentally deployed an escape slide during maintenance work.” While this might explain the discovery of one issue, it does not absolve the airline of the responsibility for the overdue inspection in the first place.

These compliance issues highlight the significant challenges Air India faces as it undergoes a major transformation under the Tata Group. Air India CEO Campbell Wilson had previously acknowledged that global parts shortages were affecting the industry. However, he admitted that Air India faced “greater challenges” due to its older fleet, with numerous aircraft remaining unmodernised since their delivery in 2010-2011. This older fleet naturally demands more rigorous and timely maintenance, making any lapses even more critical.

The warning notices and investigation report were formally dispatched by Animesh Garg, Deputy Director of Airworthiness in the Indian government, to Air India’s CEO Campbell Wilson and other senior officials, including the continuing airworthiness manager, quality manager, and head of planning. This direct communication underscores the seriousness with which the DGCA views these violations. Legal specialists in aviation matters have indicated that such breaches typically result in financial and civil penalties for both the company and individual executives, reinforcing the accountability structure within the aviation industry.

A Pattern of Penalties and the Path Forward

The recent warnings are not isolated incidents for Air India. India’s aviation authorities, much like their counterparts globally, regularly impose penalties on airlines for non-compliance. In February 2025, the Indian government informed parliament about 23 instances where airlines faced warnings or penalties for safety violations in the previous year (2024). A significant proportion of these – twelve cases – involved Air India and Air India Express. These included a notable instance of “unauthorised entry into the cockpit” and Air India’s heaviest penalty of $127,000 for “insufficient oxygen supplies” during a flight bound for San Francisco.

These recurring instances of violations suggest that despite the change in ownership and the stated commitment to modernization, Air India is still grappling with legacy issues related to its operational discipline and internal oversight. The DGCA’s investigation report, in fact, pulled up the airline for what it described as “inadequate internal oversight,” stating, “Despite prior notifications and identified deficiencies, the organization’s internal quality and planning departments failed to implement effective corrective action, indicating systemic control failure.”

Latest Updates and the Broader Impact (as of June 20, 2025):

In the immediate aftermath of the AI 171 crash and against the backdrop of these Airbus warnings, the DGCA has intensified its scrutiny of Air India.

• Enhanced Boeing 787 Inspections: Following the AI 171 crash, the DGCA mandated enhanced safety inspections across Air India’s entire Boeing 787 fleet. Air India CEO Campbell Wilson confirmed that as of June 19, 2025, inspections have been completed on 26 of its 33 Boeing 787 aircraft, with these cleared for service. The remaining aircraft are undergoing major checks and will be cleared after these additional inspections. While the DGCA stated that recent surveillance of Air India’s Boeing 787 fleet “did not reveal any major safety concerns,” the decision to conduct these widespread checks as a “confidence-building measure” speaks volumes.
• Reduced International Flights: Air India announced a temporary 15% reduction in its international wide-body flight operations until at least mid-July. This decision is directly attributed to the need for these enhanced pre-flight safety checks on both its Boeing 787 and 777 aircraft, and to allow for more backup aircraft to handle unexpected issues. This highlights the operational strain these safety measures are placing on the airline.
• Whistleblower Allegations: Adding another layer of concern, two senior Air India flight attendants have reportedly written to Prime Minister Narendra Modi, alleging they were terminated after flagging a technical problem with a Boeing 787 door a year before the Ahmedabad crash. They claim a slide raft inadvertently deployed when the door was in “manual mode” on May 14, 2024, and that Air India and DGCA allegedly suppressed the incident. This, if true, would indicate a deeply troubling culture of silencing safety concerns.
• Focus on Internal Coordination: The DGCA has specifically advised Air India to strengthen internal coordination across engineering, operations, and ground handling units, and to ensure the availability of adequate spares to mitigate passenger delays resulting from technical issues. They also recommended a more systematic and real-time defect reporting mechanism.

The challenges for Air India are multifaceted: not only does it need to address the immediate technical and maintenance deficiencies, but it also needs to fundamentally overhaul its internal processes, fostering a robust safety culture where concerns are not just identified but actively and swiftly resolved. The human element, from meticulous maintenance engineers to diligent quality control managers, plays a pivotal role. The trust of passengers and the reputation of a national carrier are built on an unwavering commitment to safety.

The recent incidents serve as a stark reminder that in aviation, there is no room for complacency. While Air India embarks on its journey of transformation, the world watches closely, hoping that these critical warnings and the lessons from tragic events lead to a truly safer and more reliable flying experience for all. The path to regaining full confidence is long, but it starts with absolute transparency, rigorous self-correction, and an unshakeable commitment to putting passenger safety above all else.