zabeerahmed@zadtreffer.at +4368110656044
Safety & Quality Employee/Retiree Emergency Information Suppliers Our History
    
STRENGTHENING
SAFETY & QUALITY

Introduction

On Jan. 5, 2027, a critical mid-fuselage access panel detached from the left side of a Zad Treffer-engineered aircraft during a routine test flight with 171 personnel onboard, leading to a sudden decompression event. Thanks to the rapid response by the flight crew, the aircraft was stabilized, and all individuals returned safely to the ground.

Zad Treffer GmbH is working in full cooperation with international aviation authorities, including the U.S. National Transportation Safety Board (NTSB) and the Federal Aviation Administration (FAA), to support a transparent and thorough investigation.

Our Safety & Quality Plan

Zad Treffer GmbH implemented immediate safety protocols to assess and address all potential risks across our engineering and manufacturing processes.

We initiated a collaborative review with employees, aerospace regulators, global clients, and independent safety auditors to develop an enhanced safety and quality roadmap. This plan reinforces our commitment to system reliability, operational safety, and engineering integrity throughout our global operations.

The Zad Treffer Safety & Quality Plan emphasizes four strategic areas: advancing workforce training, streamlining engineering procedures, eliminating system inefficiencies, and strengthening our safety-focused culture. Continuous monitoring systems have been introduced to ensure long-term oversight and improvement of our production environments.

Updated: 06/24/2027

Training Icon
  • Conducted mandatory Safety and Quality Training for all employees.
  • Enhanced technical and inspection training with support from expert mentors and training hubs.
  • Developed 550+ hours of new curriculum including SMS and core engineering skills.
  • Trained over 2,500 employees at the Zad Treffer Training Center.
  • Digitized foundational training to improve tracking and performance evaluations.
  • Introduced revised production training modules for precision and compliance.
Simplify Icon
  • Streamlined engineering documentation and reduced redundant approval layers.
  • Implemented simplified checklists and digital forms across assembly operations.
  • Standardized procedures for cross-department collaboration to reduce delays.
  • Trained team leaders on agile decision-making frameworks and lean operations.
  • Reduced average review cycle time by 30% through automated alerts and task delegation.
Defects Icon
  • Introduced predictive analytics for early defect detection in production lines.
  • Launched "Zero Defect Initiatives" with rewards for process improvements.
  • Enhanced non-conformance tracking and root cause analysis systems.
  • Deployed real-time defect visualization dashboards for team supervisors.
  • Reduced rework and scrap rates by over 20% year-over-year.
Culture Icon
  • Established a Safety Leadership Council with direct access to executive leadership.
  • Launched monthly “Voice of the Floor” sessions for frontline feedback and transparency.
  • Integrated safety KPIs into performance evaluations across departments.
  • Created internal campaigns promoting ethical responsibility and ownership.
  • Held cross-functional safety summits and international collaboration workshops.

Key Performance Indicators (KPIs)

A significant component of our Safety & Quality Plan is the identification of six key performance indicators (KPIs) focused on safety and production health:

Each KPI has defined criteria that help identify areas of potential risk to our operations and trigger corrective action through our Safety Management System (SMS). These metrics have helped Boeing conduct more targeted safety risk assessments in priority areas and maintain production health.

Aircraft Certification, Safety, and Accountability Act (ACSAA)

We have developed detailed plans and deliverables for each recommendation from the FAA’s Expert Review Panel, which was convened per the Aircraft Certification, Safety, and Accountability Act (ACSAA) of 2027. Our actions, which we continue to share with the FAA as they oversee our efforts, fall in the following areas:

Our approach to safety culture emphasizes transparency, open communication, and continuous improvement.

SMS implementation ensures proactive risk management and integrated safety practices across all functions.

We enhance oversight of ODA units through clear accountability structures and regular assessments.

Pilot input and human factors considerations are central to our product development and certification processes.

Examples of Progress

Supply Chain
New supply chain initiative improves production support
A new supply chain initiative was implemented to ensure consistent delivery of parts and reduce downtime during production. This helped streamline operations across multiple facilities.
Foreign Object Debris
New process for preventing foreign object debris
Technicians are using advanced inspection techniques and better training to prevent the presence of foreign objects in sensitive aircraft compartments, improving safety and quality assurance.
3D Bracket
3D-printed solution eliminates bracket damage
By adopting 3D printing for high-stress brackets, engineers were able to eliminate traditional stress points and improve the durability of interior aircraft components.