The Air India Flight 171 crash on June 12, 2025, was one of the most catastrophic air disasters in recent memory. Just moments after taking off from Ahmedabad’s Sardar Vallabhbhai Patel International Airport, the Boeing 787-8 plunged into a residential area, resulting in 260 deaths—241 onboard fatalities, 19 on the ground, and one miraculous survivor.
The crash sparked intense public grief, scrutiny of aviation safety standards, and international interest due to the mysterious and unprecedented cause revealed by the preliminary AAIB report: both fuel control switches had moved to the “CUTOFF” position, causing dual engine flameout. This singular act shut down all propulsion in the critical phase of takeoff, sealing the aircraft’s fate within seconds.
Timeline of Events: From Takeoff to Tragedy in Under 60 Seconds
- 13:37:37 IST: Takeoff initiated.
- 13:38:39 IST: Aircraft lifted off the runway, reaching approximately 3,000 feet.
- 13:38:40 IST: Both fuel control switches simultaneously moved from “RUN” to “CUTOFF,” causing instantaneous engine shutdown.
- 13:38:50 IST: The first officer attempted to return one switch to RUN, then the second followed four seconds later.
- 13:38:56 IST: Aircraft entered an unrecoverable descent, stall warnings blaring.
- 13:39:05 IST: Final “Mayday” issued. Seconds later, the aircraft impacted near Bopal village.
Despite emergency relight mechanisms engaging automatically, the plane had insufficient altitude or airspeed to recover, resulting in a high-energy impact.
What Are Fuel Control Switches and Why Do They Matter?
Fuel control switches are part of an aircraft’s engine fuel metering system. They control whether fuel is being supplied to the engines, and thus whether they operate or shut down.
Key features:
- Each engine on the 787 has a dedicated switch, which needs to be in RUN mode during normal operations.
- Switching to CUTOFF instantly stops fuel flow, which leads to engine flameout.
- Designed with stop-locks and lift guards to prevent accidental activation.
- Typically used during engine shutdown procedures, like after landing or in an emergency requiring engine cutoff (e.g., fire or damage).
These are not meant to be touched mid-flight, especially not during takeoff. Their placement on the central pedestal, near the thrust levers, is standard but requires vigilance.
Psychological Factors: Could Pilot Error Have Played a Role?
Aviation psychologists and human factors experts are deeply analyzing the cockpit voice recordings.
“Why did he cut off?”
“I didn’t do it.”
…suggest confusion and lack of awareness about who performed the action.
Possible scenarios under investigation:
- Miscommunication between pilot and co-pilot during a checklist or manual input.
- Startle effect due to an unrelated alert (e.g., vibration, stall warning), leading to inadvertent hand movement.
- A reflexive reaction mistaking the fuel control switch for a similar nearby control, like the autothrottle or TOGA switches.
- A malicious action (extremely rare but not ruled out in aviation investigations).
- Electrical signal misrouting triggering uncommanded switch movement (though mechanically unlikely).
Did the Switch Mechanism Fail?
Mechanically, for the fuel switches to move to “CUTOFF,” a pilot must:
- Pull the switch upward to disengage the safety lock.
- Physically push the switch downward to “CUTOFF.”
This process makes accidental activation difficult. However, FAA reports in 2018 warned that:
“If the locking mechanism is disengaged during maintenance or over time, it may allow unintended movement.”
Whether this was the case with Air India’s VT-ANB aircraft is under scrutiny.
Investigators have found no confirmation that Air India performed preventive checks related to that advisory, which was non-binding.
What Happens to a Boeing 787 After Dual Engine Flameout?
The Boeing 787 is equipped with automated re-light systems and a Ram Air Turbine (RAT) that deploys to power critical avionics if both engines fail. But these tools:
- Do not restore thrust immediately; re-light takes 15–20 seconds if altitude and airflow permit.
- Require minimum airspeed and altitude to work—conditions that did not exist during AI 171’s steep climb.
Once the engines flamed out, and even after switches were turned back to RUN, the aircraft had no forward thrust, leading to rapid deceleration, stall, and uncontrolled descent.
Broader Context: Fuel System Incidents in Aviation History
The Air India 171 crash is tragically unprecedented due to its root cause, but there are some past parallels:
- Air Transat Flight 236 (2001): Fuel leak led to dual-engine flameout. Pilots glided for 19 minutes and landed safely.
- British Airways Flight 38 (2008): Fuel restriction due to ice led to engine failure just before landing.
- Eastern Air Lines Flight 401 (1972): Distracted pilots accidentally disengaged autopilot during a bulb replacement, crashing the plane.
International Response and Policy Implications
Air India’s Measures:
- All 787s grounded for fuel switch inspection.
- Flight crew records, simulator data, and maintenance history under review.
- A task force formed to audit all critical cockpit switch design protocols.
Boeing’s Position:
- Issued a statement of full cooperation.
- No grounding order issued globally for 787s.
- Likely to face pressure to review cockpit switch designs.
Regulatory Outlook:
- DGCA India, FAA, and EASA may introduce mandatory fuel control switch inspections.
- Possibility of a redesigned locking mechanism.
- Training programs may update checklist protocols to reinforce switch awareness.
Victims, Families, and Public Reaction
The emotional toll has been massive:
- Many families lost multiple members.
- Public vigils and protests have erupted demanding accountability and compensation.
- Survivors and families accuse Air India of “neglecting warnings” and “hiding maintenance history.”
“They told us this plane was safe. If it was safe, why did it fall out of the sky in less than a minute?”
What the Final AAIB Report May Reveal
Expected in early 2026, the final report may include:
- Voice and data recorder correlation
- Simulation of control actions
- Mechanical testing of the actual switches
- Comparative analysis with global 787 fleet
- Timeline of Air India’s maintenance history
FAQs – Air India 171 Crash Explained Further
1. What exactly triggered the crash?
The fuel control switches were turned to “CUTOFF” during takeoff, leading to total engine shutdown.
2. Who turned the switches off?
The preliminary report doesn’t assign blame. Investigations are ongoing.
3. Was this a design flaw?
Possibly. FAA had issued a previous advisory on switch locking issues. Final report may confirm.
4. Was this sabotage or pilot suicide?
No evidence suggests sabotage or suicide. Investigators are still reviewing all data.
5. Could autopilot or automation have triggered the cutoff?
Not likely. The 787’s fuel switches are manual only.
6. Did Air India follow FAA guidelines?
There’s no indication that VT-ANB was inspected post-advisory. The advisory was not mandatory.
7. Will Boeing face penalties?
That depends on the final report. If the switch design is found deficient, penalties and lawsuits may follow.
8. Has this happened on other 787s?
No prior cases of simultaneous fuel switch cutoff mid-air have been reported.
9. What safety changes are expected now?
Likely revisions to switch design, mandatory inspections, and improved pilot procedures.
10. Who survived the crash?
One passenger, Vishwakumar Ramesh, survived with critical injuries and is recovering in Ahmedabad.
Conclusion: A Complex Case That Could Reshape Aviation Safety
The Air India Flight 171 crash is a haunting reminder that even in the era of ultra-modern aviation, human-machine interaction still holds immense risk. Whether the cause was pilot error, design flaw, or latent system failure, the tragedy underscores one truth:
Every switch, checklist, and design choice matters—especially when hundreds of lives are in the balance.
As global regulators await the final report, the industry must re-evaluate cockpit ergonomics, pilot training, and fuel system safety. The loss of AI 171 should be more than a tragedy—it should be a turning point in aviation history.
Report by Toofan Express