Air India announced on Monday that it has temporarily grounded one of its Boeing Dreamliners after a pilot reported a potential issue with the aircraft’s fuel control switch—an investigation that is linked to a fatal crash from last year.
The airline didn’t specify what type of defect was detected or provide any details about the specific flight involved. However, sources indicated that the pilot flagged the problem after the plane arrived in Bengaluru, India, following its departure from London.
In response, Air India confirmed that the aircraft has been taken out of service and that the original equipment manufacturer (OEM) is being brought in to prioritize checkups based on the pilot’s concerns. The airline also stated that this issue has been communicated to India’s civil aviation authority.
Neither Boeing nor the Indian civil aviation authority responded immediately to requests for comment.
The carrier, part of the Tata Group and owned by Singapore Airlines, has been under heavy scrutiny since a Dreamliner crash in June of the previous year that resulted in 260 fatalities.
Following last year’s incident, Air India carried out inspections on the fuel control switches across all Boeing 787 planes in its fleet, finding no problems.
A cockpit voice recording from the June 12 flight suggested that the captain had shut off fuel flow to the engines—a detail that is part of the early analysis by U.S. officials, according to sources.
A firefighter stands by the wreckage of an Air India Boeing 787-8 Dreamliner in Ahmedabad, India, on June 13, 2025. — Reuters
CEO notes that the report clarified some points but also raised new questions.
Wilson advises against hasty conclusions.
Memo states no findings regarding pilots’ health status.
NEW DELHI: A preliminary inquiry into last month’s crash of an Air India passenger plane that resulted in 260 fatalities has produced further questions, indicating that the investigation is ongoing, according to a memo from the airline’s CEO.
The preliminary report released by India’s Aircraft Accident Investigation Bureau described a state of confusion in the cockpit just before the Boeing Dreamliner went down.
In a memo shared with staff, Air India CEO Campbell Wilson remarked that the report has led to “new rounds of speculation in the media… It unsurprisingly brought some clarification while also raising additional questions.”
He further stated, “The preliminary report did not identify a cause and made no recommendations, so I encourage everyone to refrain from drawing hasty conclusions as the investigation is far from complete.”
The memo indicated that no mechanical or maintenance issues were found, and all required maintenance procedures had been adhered to.
The Boeing 787 Dreamliner, which was en route to London from Ahmedabad, India, started to lose thrust and altitude shortly after takeoff. Tragically, all but one of the 242 individuals onboard, along with 19 others on the ground, lost their lives.
The AAIB report highlighted that, during the flight’s final moments, one pilot was recorded inquiring about the other pilot’s decision to cut off the fuel supply.
“The other pilot insisted that he did not do so,” the report noted, adding that the fuel cutoff switches for the plane’s engine two were activated almost simultaneously, although it did not specify how.
The preliminary findings did not suggest any immediate actions for Boeing or GE, which supplied the engines for the aircraft.
ALPA India, representing Indian pilots within the International Federation of Air Line Pilots’ Associations, has dismissed any assumptions of pilot error and called for a “fair and fact-based investigation.”
“The pilots had successfully passed their mandatory pre-flight breathalyzer tests, and there were no concerns regarding their medical status,” Campbell emphasized in his memo.
The captain of the Air India flight was Sumeet Sabharwal, 56, who logged a total of 15,638 flying hours and served as an instructor for Air India, according to the Indian government. His co-pilot was Clive Kunder, 32, with 3,403 flight hours to his credit.
Air India is facing intensified scrutiny on multiple fronts following the crash.
On July 4, the European Union Aviation Safety Agency announced an investigation into Air India Express, the budget arm of the airline, after a Reuters report revealed that the airline had delayed replacing engine components on an Airbus A320 as required and fabricated records to indicate compliance.
A fire officer stands next to the wreckage of the Air India Boeing 787-8 Dreamliner in Ahmedabad, India, on June 13, 2025. — Reuters
The Boeing 787 crash resulted in the deaths of 260 individuals last month.
The pilots were experienced, but it’s unclear why the fuel switches activated.
One pilot questioned the other about shutting off the fuel.
A preliminary report has revealed confusion in the cockpit moments before an Air India jetliner crashed, leading to 260 fatalities last month. The plane’s engine fuel cutoff switches appeared to have flipped almost simultaneously, cutting fuel to the engines.
The Boeing 787 Dreamliner was on its way to London from Ahmedabad when it suddenly lost thrust and began to descend, according to Indian accident investigators who released their findings on Saturday—the deadliest aviation incident in a decade.
This report from India’s Aircraft Accident Investigation Bureau (AAIB) about the June 12 crash shortly after takeoff raises concerns over the positioning of the vital engine fuel cutoff switches, suggesting that neither Boeing nor the engine manufacturer GE was at fault.
The crash poses a significant challenge for Tata Group as it seeks to enhance Air India’s image and modernize its fleet after acquiring the airline from the government in 2022.
CCTV footage shows that shortly after takeoff, a backup energy device known as a ram air turbine deployed, indicating a loss of engine power.
In the flight’s last moments, one pilot is heard asking the other why he had cut off the fuel, to which the co-pilot replied that he hadn’t done so, according to the report. The report did not specify which comments were made by the captain or the first officer, nor did it clarify who issued the “Mayday” call just prior to impact.
The pilot in command was Sumeet Sabharwal, 56, with over 15,600 flight hours and known to have served as an instructor for Air India. His co-pilot, Clive Kunder, 32, had approximately 3,400 flight hours.
The fuel switches were found to have flipped from ‘run’ to ‘cutoff’ just after takeoff. The preliminary report did not explain how this could have occurred during the flight.
Aviation experts have raised doubts about the likelihood of a pilot unintentionally moving the fuel switches. “If they were moved by a pilot, the question is why?” questioned U.S. aviation safety expert Anthony Brickhouse.
The report indicated that the switches were activated just a second apart, which aligns with the time it would take to toggle each one manually, as noted by aviation expert John Nance. He remarked that a pilot typically would never switch off the fuel during ascent.
Activating the cutoff switch almost immediately halts the engines and is generally used to turn off engines once a plane has arrived at the gate or in specific emergencies, such as an engine fire. The report did not mention any emergency situation necessitating an engine shutdown.
At the crash site, both fuel switches were discovered in the ‘run’ position, and there were indications that both engines relit before the crash at low altitude. The report was published at 1:30 AM IST on Saturday (8:00 PM GMT Friday).
Air India has acknowledged the report in a statement, noting their cooperation with Indian authorities but refraining from further comments.
The U.S. National Transportation Safety Board expressed gratitude to Indian officials for their collaboration and stated that no recommended actions were aimed at operators of Boeing 787s or GE engines based on the report.
The U.S. Federal Aviation Administration emphasized its commitment to following the facts of the situation and addressing any identified risks promptly.
Boeing stated that it would continue to support the investigation and its client, Air India. GE Aerospace has yet to respond to inquiries for comment.
Investigation Developments
The AAIB, part of India’s civil aviation ministry, is leading the investigation into the crash, which claimed nearly all 242 lives on board plus an additional 19 individuals on the ground.
Most aviation accidents are attributed to multiple factors, with a preliminary report required within 30 days of the incident per international guidelines and a final report expected within a year.
The aircraft’s black boxes, which include cockpit voice and flight data recorders, were retrieved shortly after the crash and later analyzed in India. These devices provide essential data such as altitude, airspeed, and final communications between pilots, which narrow down potential causes of the accident.
Air India has faced heightened scrutiny following the crash.
The European Union Aviation Safety Agency plans to investigate Air India Express, its budget airline, after reports emerged that the carrier failed to swiftly comply with directives to change engine components of an Airbus A320 and had falsified records to indicate adherence.
India’s aviation regulatory body has also reprimanded Air India for violating rules regarding the operation of three Airbus aircraft with overdue escape slide checks, and in June, it was warned about “significant violations” related to pilot duty hours.
India is optimistic about an aviation boom to fuel broader development goals, aiming to transform the country into a job-generating global aviation hub similar to Dubai, which currently manages a significant portion of its international traffic.
On June 12, 2025, a devastating accident occurred shortly after takeoff from Ahmedabad, India, involving an Air India Boeing 787 en route to London. The tragic event claimed the lives of over 200 individuals from the 242 aboard the aircraft.
Details About the Boeing 787 Dreamliner:
The Boeing 787 Dreamliner is recognized as one of the most sophisticated commercial aircraft currently in operation and is regarded for its impressive safety record, having never been involved in a fatal accident prior to this incident. Boeing has acknowledged the occurrence and is actively collecting further details.
Model Specifics: The aircraft involved, a 787-8, was delivered in 2014 and is the smallest variant among three models.
Capacity: The 787-8 generally accommodates around 248 passengers, while the larger 787-9 can hold 296 passengers, and the 787-10, though having a reduced range, seats up to 336 passengers.
Engine Options: The twin-engine 787 offers a choice between engines from GE Aerospace and Rolls-Royce. The engines on this ill-fated plane were supplied by GE, which has committed to assisting with the investigation.
Sales Figures: Boeing has sold more than 2,500 units of the 787, including 47 to Air India. Although 1,189 jets have been delivered to airlines, the company has faced challenges with production delays in recent years.
Innovative Design: The 787 entered service in 2011 after overcoming development setbacks. Its advanced design uses lightweight composite materials and enhanced electrical systems that promise fuel efficiency improvements of up to 20%.
Impact on Aviation: The efficiency and range of the 787 have facilitated new route openings, often bypassing traditional hubs serviced by larger models such as the Boeing 747 and Airbus A380, ultimately affecting the production of these larger jets.
Outsourcing Approach: The manufacturing process for the 787 involved significant outsourcing, with parts and structures sourced globally before assembly at facilities in Everett, Washington, and North Charleston, South Carolina. However, this strategy resulted in supply chain challenges, leading Boeing to reassess its approach.
Previous Incidents:
In July 2013, a vacant Ethiopian Airlines 787 caught fire on the ground at Heathrow Airport in London due to a short-circuit in an emergency locator transmitter.
That same year, global regulators temporarily grounded the 787 fleet after incidents of lithium battery overheating on two Japanese aircraft in Tokyo and Boston, prompting design modifications to mitigate the risk of thermal runaway.
In March of the previous year, a LATAM Airlines 787 experienced a sudden drop during a flight from Sydney to Auckland, injuring at least 50 people. Investigators looked into an unintentional forward movement in the pilot’s seat as a possible cause.
This tragic event serves as a heartbreaking reminder of the unpredictability of air travel and highlights the need for ongoing vigilance in aviation safety.
