An engine malfunction on a Ryanair aircraft during takeoff in Greece last month caused a man’s head to be pulled out of a shattered window before being rescued by fellow passengers, according to U.S. investigators. The incident involved a broken fan blade in the right engine of the Boeing 737-800, leading to damage on the aircraft’s fuselage. The preliminary report by the U.S. National Transportation Safety Board (NTSB) revealed that bird remains were found inside the engine, hinting at a possible bird strike during takeoff.
The man, aged 61, suffered injuries to his neck, shoulder, and friction burns as a result of the incident. Flight attendants reported hearing loud vibrations and seeing smoke or fog in the cabin, prompting the release of emergency oxygen masks. Passengers reacted swiftly to assist the man whose head was stuck outside the damaged window, pulling him back inside the cabin for safety.
Maintenance records indicated that the fan blades underwent inspections, showing no prior damage. However, flight crews had reported multiple suspected bird strikes on the same engine in the past year. The NTSB highlighted the importance of examining the inspection procedures and the potential impact of previous bird strikes on the engine’s condition.
Ryanair announced its decision to withhold further comments until the NTSB concludes its investigation, with Boeing and CFM International providing assistance. The Federal Aviation Administration (FAA) had issued directives in 2025 to strengthen engine coverings on Boeing 737s following previous incidents involving fan blade failures. The mandated modifications aim to prevent engine coverings from detaching if a fan blade malfunctions.
The NTSB report indicated that the necessary changes had not been implemented on the Ryanair aircraft. The FAA and NTSB might reassess the deadline for these modifications in light of the recent incident. The FAA refrained from commenting on the ongoing investigation but emphasized its commitment to ensuring aviation safety based on evidence.
The aircraft involved in the incident, a 737-800 with a capacity of up to 189 passengers, was delivered to Ryanair in 2008. Flight data revealed that the plane ascended to a certain altitude before descending to burn fuel and safely return to Thessaloniki. Operated by Malta Air, a Ryanair subsidiary, the flight landed without further complications, and passengers disembarked at the airport terminal.