Boeing Flying the Wings Off 787 and 747-8F

This past few days since the Farnborough Air Show ended has seen Boeing flying the wings off both the 787 and the 747-8F. The 787 test fleet racked a few first during this past weekend including ZA001 and ZA002 going over the 400 flight hour mark. the 787 test flight fleet surpassing the 40% mark for test flight hours and the 400th flight of the 787.

During Sunday all 5 test 787s were flying at one point or another and Boeing had added well over 65 test flight hours during the period starting from July 23rd to July 25th. Boeing will need to fly the 4 Rolls Royce powered 787s about 10 hours a day combined everyday until the end of November if they hope to deliver the first 787 to ANA by the end of the year.

So far Boeing has accumulated about 1,293 flight hours on the 787 though I think their total is missing one flight. Boeing is also almost half way through to certifying the Trent 1000 powered 787. That version of the 787 needs 2,430 flight hours and Boeing has accumulated a little over 1,200 flight hours on the Trent powered aircraft. The test flight program for the GEnx-1B engines is just getting started and Boeing has less than 90 hour accumulated on ZA005.

Boeing also kept the 747-8F flight crews busy during this weekend with RC 501, RC522 and RC 503 (3 of 4 test aircraft) all flying at one point during this weekend. I believe RC 521 is conducting ground tests in Victorville.

Boeing has cast some doubt on whether it can finish the test flight program and deliver both these airplanes by the end of the year though they are maintaining the guidance for deliveries to start by the end of 2010. If the current pace of test flights becomes a long term (4-5 months) trend within each of these programs, then Boeing is well on their way to start deliveries in December. Careful observation of the test flight program progress for both the 787 and the 747-8F will allow us to know how they're progressing.

Fanborough, 2010 Day 4 and 787/747-8 flight testing

As the Farnborough International Air Show drew to a close, one leaves with the feeling that the industry is slowly turning the corner after a few years in the midst of the worldwide recession. The key was lessors coming in to buy a lot of narrowbody aircraft and rebuild their portfolios. There certainly wasn't a lot of widebody aircraft ordered at this year's airshow but those orders may just be around the corner for many carriers. Airbus, as usual, made a big splash at the air shows with many orders being announced for the first time. Boeing also announced a lot of orders but many were for airplanes that they have already booked.

However the surprise of the show was how well Embraer and Sukhoi did and well Bombardier did not. This may be a sign of things to come in the commercial airline industry and it serves as a warning to Airbus and Boeing.

Airbus:
Aeroflot - 11 x A330-300
Air Lease Corp - 31 x A320, 20 x A321
Garuda Indonesia - 6 - A330-200
GECAS - 60 x A320
Germania - 5 x A319
Hong Kong Airlines - converted 15 XA330 to 15 x A350 (MoU) ordered 10 x A330 (MoU)
LAN - 50 x A320 (MoU)
RBS Aviation - 53 x A320 (previously booked as unidentified customer)
Thai Airways - 7 x A330-300 (MoU)
Virgin America - 40 x A320 + 20 x A320 options (MoU)
Total - 5 x A319, 91 x A320, 20 x A321, 17 x A330

ATR:
Air Lease Corp - 10 x ATR-72-600
Azul - 20 x ATR-72-600
Golden Airlines - 2 x ATR-72-500
Lao Airlines - 2 x ATR-72-500
Total - 30 x ATR-72-600, 4 x ATR-72-500

Boeing:
Air Lease Corp - 54 x 737 + 6 x 737 (options) (MoU)
Air Austral - 2 x 777-200LR (previously booked as an unidentified customer)
Alaska Airlines - 2 x 737-800 previously booked as an unidentified customer)
American Airlines - 35 x 737-800 (not announced at Farnborough)
Avolon Air Lease - 12 x 737 (ordered in 2009)
AzerBaijan Airlines - 1 x 767-300ER, 1 -767-300F, -2 x 737
Emirates - 12 x 777-300ER (30 total, 18 were previously ordered this year as an unidentified customer)
GECAS - 40 x 737-800
Norwegian Air Shuttle - 15 x 737-800 (exercise of purchase rights)
OK Airlines - 10 x 737-800 (previously booked as an unidentified customer)
Qatar Airways - 2 x 777-200LR (previously booked as an unidentified customer)
RBS Aviation - 43 x 737-800 (previously booked as an unidentified customer)
Royal Jordanian Airlines - 3 x 787-8 (previously ordered as an unidentified customer)
Total - 90 x 737, 2 x 767, 12 x 777-300ER

Bombardier:
QANTAS Airways - 7 x Q400
Qatar Airways - 2 x G5000 Business Jets, 1 x Challenger 605
UFO Russian Customer - 4 x Global Express XRS
Vista Jet - 4 x Global Express XRS, 2 x Challenger 605
Total - 10 x G5000 & Global XRS, 3 x Challenger 605, 7 x Q400

Embraer:
Air Lease Corp - 15 x E190
Azul - 5 x E195
Flybe - 35 x E175
Republic Airlines - 24 x E190 (LoI)
Trip Airlines - 2 x E190
Total - 35 x E175, 17 x E190, 5 x E195

Sukhoi:
Kartika Airlines - 30 x SSJ-100 Super Jets (MoU)
Orient Thai Airlines - 12 x SSJ-100 Super Jets
Pearl Airways - 30 x SSJ-100 Super Jets
Total - 42 x SSJ-100

787 and 747-8 Test Flying

Yesterday, Boeing flight test division got very busy. They flew 3 of 4 747-8F and 4 of 5 787s. This included the first flight of RC503, the second production 747-8F that will be delivered to Cargolux late this year or early next year. Boeing is trying to make up ground in the 747-8 flight test program.

The 747-8F program has the most ground to make up and Flightblogger has an article explaining why the program is behind. Read it here:

Flightblogger: In Context: Why Boeing's Jumbo Freighter May Slip to 2011

The 787 got a big lift with many of the test flight airplanes flying during the day though not all at the same time. ZA001 took the longest test flight of the day which clocked in at just under 8 hours. Boeing will need to fly the Rolls Royce powered 787s at least 10 hours a day everyday if they hope to deliver the first airplanes to ANA by the end of this year.

Farnborough 2010, Day 3

Here's the order tally from the Farnborough Air Show today. ZA003 has flown back to Boeing Field and the four other 787s have been flying this past week so it looks like Boeing is trying to pick up the pace of flight testing on the aircraft. With ZA003's return flight back to the US, the 787 test flight fleet has gone over 1,200 flight hour flown. One note from Farnborough, Boeing invited Airbus CEO Tom Enders and salesman John Leahy to tour the 787. According to Dominic Gates of the Seattle Times all he would say is "It will be a very good airplane" after which he added a snarky remark or two about the 787 which you can read here.

Airbus:
Aeroflot - 11 x A330-300
Air Lease Corp - 31 x A320, 20 x A321
Garuda Indonesia - 6 - A330-200
GECAS - 60 x A320
Germania - 5 x A319
Hong Kong Airlines - converted 15 XA330 to 15 x A350 (MoU) ordered 10 x A330 (MoU)
LAN - 50 x A320 (MoU)
RBS Aviation - 53 x A320 (previously booked as unidentified customer)
Thai Airways - 7 x A330-300 (MoU)
Total - 5 x A319, 91 x A320, 20 x A321, 17 x A330

ATR:
Air Lease Corp - 10 x ATR-72-600
Azul - 20 x ATR-72-600
Golden Airlines - 2 x ATR-72-500
Lao Airlines - 2 x ATR-72-500
Total - 30 x ATR-72-600, 4 x ATR-72-500

Boeing:
Air Lease Corp - 54 x 737 + 6 x 737 (options)
Air Austral - 2 x 777-200LR (previously booked as an unidentified customer)
American Airlines - 35 x 737-800 (not announced at Farnborough)
Avolon Air Lease - 12 x 737 (ordered in 2009)
Emirates - 12 x 777-300ER (30 total, 18 were previously ordered this year as an unidentified customer)
GECAS - 40 x 737-800
Norwegian Air Shuttle - 15 x 737-800 (exercise of purchase rights)
OK Airlines - 10 x 737-800 (previously booked as an unidentified customer)
Qatar Airways - 2 x 777-200LR (previously booked as an unidentified customer)
RBS Aviation - 43 x 737-800 (previously booked as an unidentified customer)
Royal Jordanian Airlines - 3 x 787-8 (previously ordered as an unidentified customer)
Total - 144 x 737, 12 x 777-300ER

Bombardier:
QANTAS Airways - 7 x Q400
Qatar Airways - 2 x G5000 Business Jets, 1 x Challenger 605
UFO Russian Customer - 4 x Global Express XRS
Vista Jet - 4 x Global Express XRS, 2 x Challenger 605
Total - 10 x G5000 & Global XRS, 3 x Challenger 605, 7 x Q400

Embraer:
Air Lease Corp - 15 x E190
Azul - 5 x E195
Flybe - 35 x E175
Republic Airlines - 24 x E190 (LoI)
Trip Airlines - 2 x E190
Total - 35 x E175, 17 x E190, 5 x E195

Sukhoi:
Kartika Airlines - 30 x SSJ-100 Super Jets (MoU)
Orient Thai Airlines - 12 x SSJ-100 Super Jets
Pearl Airways - 30 x SSJ-100 Super Jets
Total - 42 x SSJ-100

Farnborough 2010, Day 2

The order bonanza continues today at the Farnborough Air Show. There were a number of MoUs for Airbus while Boeing announced a few orders some of which were already booked by Boeing. Please note that the totals below will only be for firmed orders that were announced and were not previously recorded on the order books. Here's a cumulative summary of what transpired during the day today:

Airbus:
Aeroflot - 11 x A330-300
Air Lease Corp - 31 x A320, 20 x A321
GECAS - 60 x A320
Hong Kong Airlines - converted 15 XA330 to 15 x A350 (MoU) ordered 10 x A330 (MoU)
LAN - 50 x A320 (MoU)
RBS Aviation - 53 x A320 (previously booked as unidentified customer)
Total - 91 x A320, 20 x A321, 11 x A330

ATR
Air Lease Corp - 10 x ATR-72-600
Azul - 20 x ATR-72-600
Golden Airlines - 2 x ATR-72-500
Lao Airlines - 2 x ATR-72-500
Total - 30 x ATR-72-600, 4 x ATR-72-500

Boeing:
Air Lease Corp - 54 x 737 + 6 x 737 (options)
Avolon Air Lease - 12 x 737 (ordered in 2009)
Emirates - 12 x 777-300ER (30 total, 18 were previously ordered this year as an unidentified customer)
GECAS - 40 x 737-800
Norwegian Air Shuttle - 15 x 737-800 (exercise of purchase rights)
RBS Aviation - 43 x 737-800 (previously booked as an unidentified customer)
Royal Jordanian Airlines - 3 x 787-8 (previously ordered as an unidentified customer)
Total - 109 x 737, 12 x 777-300ER

Bombardier:
Qatar Airways - 2 x G5000 Business Jets, 1 x Challenger 605
Total - 2 x G5000, 1 x Challenger 605

Embraer
Air Lease Corp - 15 x E190
Azul - 5 x E195
Flybe - 35 x E175
Trip Airlines - 2 x E190
Total - 35 x E175, 17 x E190, 5 x E195

Sukhoi:
Kartika Airlines - 30 x SSJ-100 Super Jets
Orient Thai Airlines - 12 x SSJ-100 Super Jets
Total - 42 x SSJ-100

There appears to be a big order announcement from Qatar Airways as well as rumors of a Bombardier announcement possibly for the C-Series.

Farnborough 2010, Day 1

While yesterday's attention was focused on the arrival of the 787 to Farnborough and part of today's attention was focused skywards on the flight displays, there were some order announcements that were announced today. Here's a summary of what transpired during the day today:

Airbus:
Aeroflot - 11 x A330-300
Air Lease Corp - 31 x A320, 20 x A321
GECAS - 60 x A320
Total - 91 x A320, 20 x A321, 11 x A330

Boeing:
Emirates - 12 x 777-300ER (30 total, 18 were previously ordered this year as an unidentified customer)
GECAS - 40 x 737-800
Norwegian Air Shuttle - 15 x 737-800 (exercise of purchase rights)
Total - 55 x 737-800, 12 x 777-300ER

Bombardier:
Qatar Airways - 2 x G5000 Business Jets, 1 x Challenger 605
Total - 2 x G5000, 1 x Challenger 605

Sukhoi:
Kartika Airlines - 30 SSJ-100 Super Jets
Total - 30 x SSJ-100

One note about the Emirates order for the 777-300ER, this order is meant to replace the 737 order from DAE Capital that had placed huge orders for both Boeing and Airbus products in 2007 at the Paris Air Show. This is according to a report by Dominic Gates of the Seattle Times. So this is not a new revenue order for Boeing. This is going to be true for Airbus where the 32 A380s that Emirates ordered at the Berlin Air Show was a replacement of DAE's Airbus order. Read Dominic's post HERE.

Apparently there will be more orders for both large manufacturers and possibly Bombardier (for the C-Series), if Qatar Airways and P&W can overcome hurdles in their negotiations. Look for Air Lease Corp (Steven Udvar-Hazy's new airplane leasing company) to order the 737-800 as well as Saudi Arabian Airlines to order the 777-300ER (though this may be an order that is already booked on Boeing Order web site). Airbus may receive and order for up to 70 A320s from LAN Airlines. There is also a rumor of Turkish placing an order for both the A350 and the 787 at the air show but that's unconfirmed. Boeing and Airbus have both promised more order announcements over the next few days.

787 in Farnborough

Thanks to Jon Ostrower and Flightglobal for the video

Boeing announced the arrival of the 787 at the Farnborough International Air Show after the aircraft, ZA003 (flying as BOE787), landed a the Farnborough Field after a nine and a half hour flight. This is the international debut of the 787. Boeing said the crew and test engineers aboard conduct flight test along the way. Here's Boeing's press release:

News Release Issued: July 18, 2010 11:34 AM EDT

Boeing 787 Dreamliner Makes International Debut

FARNBOROUGH, United Kingdom, July 18 /PRNewswire-FirstCall/ -- The Boeing (NYSE: BA) 787 Dreamliner made its international debut landing at the Farnborough Airport at 9:09 a.m. (local time) in support of the Farnborough International Airshow that begins Monday.

"It's an honor to showcase the 787 here at the Farnborough Airshow," said Scott Fancher, vice president and general manager of the 787 program, Boeing Commercial Airplanes. "I can't think of a finer stage on which to present this highly anticipated airplane."

This is the first international trip made by a Boeing 787 Dreamliner. The airplane came via nonstop flight to Farnborough, U.K., from Seattle.

"We took advantage of the flying time to conduct some flight testing on the way," Fancher said. "We're taking every opportunity to complete our testing requirements when we fly."

The 787 Dreamliner is built by an international team and will provide airlines around the globe with a new level of efficiency in operations, with a 20 percent reduction in fuel use when compared to similar-sized airplanes. The 787 also brings a new level of passenger comfort to travelers including bigger windows and more personal space as well as an environment designed to help them arrive at their destinations feeling refreshed.

Boeing executives and members of the board of directors, dignitaries from the United States and U.K. and a wide variety of media were on hand to welcome Captains Mike Bryan and Ted Grady as they stepped off the airplane and welcomed visitors aboard. About a dozen people traveled on the airplane to conduct testing during the flight.

Fancher and other Boeing executives will provide a media briefing on the 787 at the airshow's main press chalet at 10 a.m. (local time). The airplane, referred to as ZA003, will depart Tuesday afternoon, July 20.

Saj Ahmad of Fleetbuzzeditorial.com got some nice photos of the 787 at Farnborough

Saj Ahmad: Boeing 787-8 Debuts At Farnborough

Seven Months In...787 Flight Test Update

As BOE787 (ZA003) is winging its way over Canada, the North Atlantic and on to Farnborough, questions have arisen over the current pace of flight testing in the 787 program an whether Boeing can increase the pace of flight tests in order to deliver the first 787s to ANA on time by the end of this year.

Scott Fancher has raised a yellow flag of caution late last week by saying that delivery may slip by a few weeks into January of 2011. Now a few weeks in the whole scheme of things is really nothing and in context of the more than two and a half years of delays in program it's a few raindrops in a lake, however, what is concerning is that pace still has not risen to what it needs to be even if Boeing hopes to delivery in January, 2011.

As of July 14th and completing 7 full months of flight testing, the Test Flight Fleet has amassed over 1,162 flight hours. This is not even 40% of the required 3,100 flight hours that Boeing needs to certify both the Rolls Royce and GE versions of the 787. If Boeing hopes to certify at least the Rolls Royce version, they've got over over 1,200 flight test hours to complete over the next four and half months...that's pace of over 266 flight hours per month the Rolls Royce powered airplanes...not an easy task given the current pace of test flights. In June Boeing flew only 49 test flight though they did fly for over 209 flight hours. This still is down from the previous month (May) where Boeing flew 104 flights and accumulated over 349 flight hours. July is not looking much better with over 96 flight hours flown thus far.

Another area of concern is that the GE powered 787s are due to be delivered to some major airlines such as JAL, Air India, RAM and Continental but only one of the GE powered aircraft is flying (and flying a lot). The last GE powered 787, ZA006 is still on the ground and program sources have told me it may not fly until early September. It does seem to me that there will be a delay in delivering the GE powered airplanes to customers as a little over 9% of the needed GE fight hours have been flown and the second airplane that's needed won't be off the ground until early September. The pace of test flight on ZA005 will be watched to see if Boeing can get the GE powered 787 certified in time. Of course the pacing item will still be getting the over 2400 hours on the Rolls powered airplanes completed by early December at the very latest.

You can check out my latest tracking of the 787 test flight progress below:

ZA003 to fly to Farnborough this evening

Boeing has filed the flight plan for it's third 787 to fly to Farnborough in the first transcontinental flight of the 787 since test flights began 7 months ago. Usually ZA003 flies under the flight number of BOE003 but for this special occaision the 787 is flying there and back under the flight number of BOE787. The flight plan calls for an expected arrival time of 7:30 AM on Sunday morning but Boeing has said the airplane will arrive at about 9 AM. The difference is due to test flying around the North Pole to test the inertial navigation system where ZA003 will fly in figure 8s and then proceed to Farnborough Field.

Thsi will be the first 787 flight abroad and this appearance at the show is of huge importance to Boeing to demonstrate that the program is past the hurdles that have plauged to program for the past two and a half years despite the warning from Scott Fancher that deliveries MAY slide into 2011. I will be putting up another post reviewing hte test flight program to date in a day or so so more on that issue in that post.

787 first delivery may slide into early 2011

In a new twist in the continuing saga that is the 787, Scott Fancher said today that the first delivery of 787 to launch customer ANA may slide into early 2011 though they are still targetting the end of 2010 for first delivery. Scott Fancher said that this is a "cautionary note" as issues that have to be resovled including the horizontal stabilizer issue has eaten away at the schedule margin in the program.

Another issue is changing out the instrumentation in the test airplanes has taken more time than Boeing had thought meaning that the aircraft is spending more time on the ground getting its test instrumentation changed out.

Seattle Times article on potential delivery slip

Flightblogger article on potential delivery slip

Additionally, Boeing said today during the conference call that first flight of ZA006 has slipped into August due to horizontal stabilizer inspections and rework. However, a source has told me that first flight for this airplane is now listed internally as September 7. If true then there may be more involved then just horizontal stabilizer rework though that is speculation on my part.

Boeing is under tremendous pressure to get deliveries going. Many carriers are trying to get early delivery slots just as QANTAS has done (for its Jetstar subsidiary) and now Aeroflot and the Russian government are pressuring Boeing to deliver the 787 before the 2014 Winter Olympics in Sochi, Russia.

Aubrey Cohen of the Seattle PI has a great article on todays news from Boeing:

Aubrey Cohen's 787 blog post

On a final note, Boeing is getting ZA003 ready for Farnborough and is even giving the airplane a bath today.

Farnborough 2010 Story: 787 Prepares for Farnborough

Flightblogger gives details of Boeing's upcoming 787 production hold

Boeing's plan to hold parts deliveries into Everett for the second time this year became more clear today when Flightblogger posted details for the plan. Airplane 27, whose parts will be delivered in about a month, will be the last airplane to enter final assembly for 6 weeks.

The main impetus behind the temporary stop is to allow suppliers to catch up with the rest of the supply chain. There is still a lot of travelled work flowing into Everett mostly coming from Boeing's North Charleston plant. The ultimate aim is to have all parts arriving from suppliers into Everett to have a 100% completion rate starting with airplane 28 (ZA232) for Air India. Flightblogger says that suppliers of items such as doors, floor grids and wiring (with the floor grids being the most critical) are holding up the ability for parts to be delivered fully complete into Everett.

Flightblogger ends with two important points. The first is that when airplane 28 arrives at Everett it will signal that start of production going to almost 3/month. Flightblogger ends with this second (and most important) point:

"Yet, the question remains for Boeing: As the ramp up continues toward building 10 aircraft per month byt the end of 2013, how does the company avoid overwhelming its supply chain forcing additional halting stops and starts on its road ahead?"

This question can only be answered by the supply chain that Boeing is quite dependent on.

Read more:

Airplane 28 to follow six-week hold, 787's chance to catch up

Lastly, Boeing announced that they have settled on a site in North Charleston, SC for it 787 interiors manufacturing facility. This facility will manufacture interior parts such as stowage binds, partitions, cockpit doors and other items. Boeing expects the facility to start construction by the end of the year and should be ready in time to support the final assembly of the first 787 to roll off the North Charleston line by the end of 2011/early 2012. The facility will be 10 miles away from the final assembly line and will ad about 150 jobs to the region. Boeing is also planning to manufacture the 787 tail for North Charleston assembled 787 on site at the South Carolina facility. Currently, the tail is built at a facility in Washington State and will continue to assemble the tails for Everett built 787s.

Here's Boeing's press release:

Boeing to Manufacture Certain 787 Interior Parts in North Charleston, S.C.

NORTH CHARLESTON, S.C., July 15 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) today announced that it has chosen North Charleston, S.C., as the location for its new 787 Dreamliner interiors fabrication facility. In addition, Boeing will purchase land from Stone Mountain Industrial Park Inc. BRPH will design the facility, and Pattillo Construction will provide construction services. Employees at the facility will manufacture and assemble airplane interior parts.

"This decision is another significant step toward creating a solid aerospace presence for future generations to come in South Carolina," said Ray Conner, vice president and general manager, Supply Chain Management and Operations, Boeing Commercial Airplanes. "The selected location for our new interiors facility will provide us with the continued flexibility we need to leverage our production capability and meet the needs of our 787 customers."

The new fabrication factory will be 10 miles (16 km) from Boeing's 787 final assembly and delivery site in North Charleston. The close proximity of the two facilities will help improve the efficiency of the final assembly and delivery process in South Carolina.

The interiors fabrication facility, which was first announced in May, is expected to create more than 150 new jobs.

At the new facility, the Interiors Responsibility Center South Carolina team will manufacture 787 interior parts, including stowbins, closets, partitions, class dividers, floor-mounted stowbins used by flight attendants, overhead flight-crew rests, overhead flight attendant crew rests, video-control stations and attendant modules.

Construction is expected to begin in the fourth quarter of 2010.

787 Flight Testing picking up

787 flight test picked up this week with 4 of the 5 test airplanes, ZA002, ZA003, ZA004 and ZA005 having flown this week. ZA001 is expected to fly by this coming Sunday (July 18th) but may fly as early as today (July 15th). ZA005 had flown to Great Fall, Montana on Tuesday July 13th to test high wind performance of the 787 and did a a series of take offs and landings in winds with gusts of up to 50 mph. Boeing meteorologists were looking for those types of conditions to test the 787s high wind performance.

Coming up will be ZA003's highly anticipated flight to Farnborough the 787s first flight overseas. It should leave sometime on Saturday evening head towards to North Pole to fly figure 8s and test the navigation system and then fly on to Farnborough where it will land around 9 AM local time on July 18th after an 11 hour flight from Boeing Field. The airplane will leave Farnborough on the afternoon of the 20th to head back to Boeing Field.

6th 787 first flight delayed again; 25th 787 to start final assembly on July 12th

Boeing has delayed the first flight of ZA006, the last test flight airplane and the 2nd with GEnx engines. Sources have told me that internal schedules show the airplane having its first flight on August 30th (delayed from July 13 and July 26). No reason of the delay was known at this time.

I'm not sure but the delay may have an impact on delivery of the first GEnx powered aircraft which is to happen early next year. Boeing may opt to have some tests that were to be flown on ZA006 to be tested on ZA005, the current GEnx 787 that is flying.

Boeing will start final assembly of the 25th 787 to be built on Monday. After a line move that will put ZA006 in the ATS Hangar, ZA176 to the paint hangar, and ZA101 in building 40-24; ZA230 which is destined for Air India with GEnx-1B engines will start final assembly on July 12th. A second 787 (ZA231) for Air India will follow about two weeks later on July 27th. Boeing will start final assembly on the 27th 787 in mid August after which there will be a resequencing of part deliveries in order to allow the production system to catch up with work. At this rate Boeing should have about 36 airplanes either assembled or in final assembly at Everett. There is supposed to be a slight increase in the production rate from 2/month to 2.5/month but I'm not sure if that is still to be implemented around August/September as planned.

It's official: Boeing sending 787 to Farnborough

Boeing has pulled the trigger, as widely expected, and is sending the third 787, ZA003 to Farnborough in the aircraft's international debut. The airplane will fly into Farnborough on July 18th and will be part of the static display for two days and then will fly back to the US.

There will be specially arranged tours of the aircraft for show attendees while it is in Farnborough. The airplane will leave Farnborough on the afternoon of the 20th. Boeing will have a 787 program update on the morning of the 20th. Here's the press release by Boeing:

Boeing Plans to Debut 787 Dreamliner and New Unmanned Systems at Farnborough

CHICAGO, July 9 /PRNewswire-FirstCall/ -- The Boeing 787 Dreamliner will make its international debut this month when the doors open on the Farnborough International Airshow outside London. Boeing also will feature an extensive display of new, advanced unmanned systems and technologies.

"We've chosen Farnborough as a venue for spotlighting the breakthrough capabilities and innovations of both our commercial airplanes and our defense, space and security businesses," said Tom Downey, senior vice president, Boeing Communications. "We look forward to an optimistic mood this year as industry leaders meet amid signs of economic recovery."

The 787 flight-test airplane, ZA003, will touch down at Farnborough the morning of Sunday, July 18 and will remain on static display through mid-day July 20. The airplane will be open for tours on a scheduled basis July 19 and 20. Boeing is using ZA003 to test and certify seats, galleys and associated cabin safety and comfort systems, among other test points.

Boeing's exhibit at the show will focus on unmanned systems, including the international debut of the recently unveiled Phantom Ray demonstrator, the A160 Hummingbird and the Unmanned Little Bird. The Boeing Unmanned Systems Display will showcase more than a dozen products, including the new Integrator and the ScanEagle Compressed Carriage.

During the show's daily flying demonstration, Boeing will demonstrate the capabilities of its advanced, combat-proven, multi-role F/A-18E/F Super Hornet fighter. The company and its customers will display several other systems, including the air show debut of the 737-based Peace Eagle airborne early warning and control platform for the Turkish Air Force. Visitors also will see the C-17 Globemaster III military transport; the F-15E Eagle fighter jet; and the AH-64D Apache Longbow attack helicopter. In addition, Qatar Airways will display its newest Boeing 777-300ER July 19-22.

Boeing will hold a series of media briefings during the show, as listed below. Media at the show should check the briefing schedule daily at the Media Centre and the Boeing media chalet, situated in chalet row B 1-6, for updates.

The company will keep the news media and the public updated about activities at the show at www.boeing.com/farnborough2010 starting July 15 and through Twitter feeds: @BoeingAirplanes, @BoeingDefense and @BoeingCorporate.

Note: All times listed below are local to Farnborough

Sunday, July 18 – Tuesday, July 20

Approximately 9am Sunday – 787 Arrives Farnborough Airport*

The 787 will be available for media viewing during the following
times:

Sunday: 11.30 to 13.00

Monday: 12.00 to 13.00

Tuesday: 09.00 to 10.00
*See separate 787 media advisory for further details


Monday, July 19
09.45 Boeing Commercial Airplanes Update – Radlett Suite (Media Centre)

Boeing Commercial Airplanes President and CEO Jim Albaugh will assess current industry and market conditions and provide an update on Boeing commercial airplane products and services, development programs and product investments.

11.00 Boeing Defense, Space and Security Overview - Hatfield Room (Media Centre)

Boeing Defense, Space & Security President and CEO Dennis Muilenburg will present an overview of how BDS is repositioning for even greater global competitiveness and future growth, detailing accelerated change and highlighting opportunities in international sales and adjacent markets.

13.00 A New Generation of Air Refueling – Boeing Media Chalet Theatre

Charles Johnson, vice president, Air Force Mobility, C3/Networks and Support Systems, will discuss the importance of air refueling as a key enabler of airpower, and how Boeing's NewGen combat-ready, multi-role tanker is best suited to meet the Air Force's future refueling requirements at the lowest cost to the warfighter.

14.00 NAVAIR/Bell Boeing
V-22 Update – Boeing Media Chalet Theatre

NAVAIR V-22 Program Manager Col. Greg Masiello will provide an update on the V-22 Osprey program.

15.00 Boeing/Bigelow Aerospace – Boeing Media Chalet Theatre

Roger Krone, president of Network & Space Systems and Robert T. Bigelow, founder of Bigelow Aerospace, will discuss the Boeing/Bigelow Aerospace collaboration. Bigelow will provide an update on his plans to build an Orbital Space Complex. Boeing will provide an update on the development of critical technologies and capabilities for NASA's Commercial Crew Development (CCDev) initiative and plans to support NASA and Bigelow with a commercial crew transportation system.


Tuesday, July 20

09.30 Integrated Unmanned Solutions – Boeing Unmanned Systems Display

Darryl Davis, president of Phantom Works, and Chris Chadwick, president of Boeing Military Aircraft, will deliver a briefing on the company's broad range of Unmanned Aerial Vehicle capabilities, followed by a media walk-around of individual systems. This will be the international debut of the A160, Phantom Eye and Phantom Ray.


10.00 787 Dreamliner: From Concept to Reality – Radlett Suite (Media Centre)

Scott Fancher, vice president and general manager of the 787 Dreamliner Program; Capt. Mike Carriker, chief pilot for the 787 Program, Mike Sinnett, vice president and chief engineer for 787 Systems; and Marlin Dailey, vice president, Sales & Marketing; and John Roundhill, Commercial Airplanes Senior Advisory Group member, will provide an update on 787 development and flight test progress.

11.00 U.S. Navy F/A-18E/F and EA-18G Programs – Boeing Media Chalet Theatre

Capt. Mark Darrah, F/A-18 and EA-18G program manager, PMA-265, provides a detailed overview of the Navy's combat-deployed, frontline Super Hornet strike fighter, and its new electronic attack aircraft, the EA-18G Growler, as it readies for first deployment.

12.00 The Strike Fighter Evolution – Boeing Media Chalet Theatre

Shelley Lavender, vice president and general manager of Global Strike Systems, will discuss "the evolving strike fighter" and the new capabilities and technologies that will shape the advanced strike platforms of tomorrow.

13.00 Factory-to-Flight-Line Support – Boeing Media Chalet Theatre

A panel featuring Jim O'Neill, vice president and general manager, Integrated Logistics; Mike Kurth, managing director of Boeing Defence UK; and Phil Dunford, vice president/general manager, Rotorcraft Systems, will highlight the UK Chinook Through-Life Customer Support, Apache Support and C-17 Globemaster III Sustainment Partnership as model support programs. Customers will also be represented by Rear Adm. Tony Johnstone Burt, head of the Joint Helicopter Command, and Air Cmdr. Baz North, Deputy Chief of Air Staff.

15.00 Boeing / U.S. Navy P-8 Programs – Boeing Media Chalet Theatre

Bob Feldmann, vice president and general manager, Airborne Battle Management, and Martin Ahmad, principal deputy program manager, Naval Air Systems Command, will discuss P-8 program activities including flight testing, assembly and recent/upcoming milestones.


Wednesday, July 21

10.00 Air Battle Management – Boeing Media Chalet Theatre

Bob Feldmann, vice president and general manager, Airborne Battle Management, and Jeff Trauberman, vice president, Business Development, Boeing Network and Space Systems, will highlight the integrated approach to Battle Management/C4ISR with AEW&C, AWACS and NC3S/Vigilaire. They will also provide an update on the Wedgetail AEW&C program for Australia.

12.00 Environmental Technology Update – Boeing Media Chalet Theatre

Billy Glover, Boeing Commercial Airplanes managing director of Environmental Strategy, and Tom Bell, vice president, Boeing Military Aircraft Business Development, will brief the media on recent companywide achievements and progress in reaching environmental goals

13.00 International Rotorcraft – Boeing Media Chalet Theatre

Phil Dunford, vice president/general manager, Rotorcraft Systems, will cover an update on the Chinook, AH-6i and Apache rotorcraft programs, highlighting growing international demand and opportunities around the world.

14.00 VIP/Executive Fleets – Boeing Media Chalet Theatre

Stephen Taylor, president of Boeing Business Jets, and Tony Parasida, president, Global Services & Support, Boeing Defense, Space & Security, will detail Boeing platforms for Presidential / VIP fleet recapitalization and other special-mission derivative aircraft.

15.00 C-17 SAC – Boeing Media Chalet Theatre

Tommy Dunehew, vice president of Business Development, C-17 program, Boeing Defense, Space & Security, and Gunnar Borch, general manager of the NATO Airlift Management Agency (NAMA), will provide an update on the NATO-led Strategic Airlift Capability initiative, which this month marks its first year of operations.

Around the 787 world...an update

Well as my "real" job kept me very busy (I bet some of you didn't have to work till 4:30AM the next morning), the 787 continued its flight testing activities. So far ZA004 and ZA005 have been flying with ZA005 undertaking flutter testing with the GEnx engines configuration. ZA004 has started the important flight loads survey testing whose data will be compared to predicted data.

Flightblogger has posted a flight test update on his blog but he also revealed that ZA003 and ZA001 are undergoing horizontal stab rework. While ZA003 should finish this work by July 9th, Boeing is keeping the option of sending ZA002 to Farnborough instead of ZA003 in case the work is not completed. It has been suspected that ZA003's return from Arizona to Boeing Field meant that there may need to have some rework done on this aircraft and now it looks as if that is true.

Flightblogger: Horizontal stabilizers of ZA003 and ZA001 being reworked, ZA002 on deck for Farnborough

Guy Norris also put out an article at Aviation Week describing Boeing reaction to the horizontal stab workmanship issues and how Boeing is trying to figure out who the problem got past quality control inspections. He says that Boeing still has margin in the schedule so any rework shouldn't impact the remainder of the test schedule. Guy also gives a look ahead to the test flight schedule.

Guy Norris: 787 To Debut At Show, Despite Tail Issues

Max Kingsley-Jones of Flightglobal.com reported that the 787 fatigue test airframe, ZY998, is about to start it's 3 year testing of the durability of the 787 airframe. The airframe will undergo rigorous testing which will subject it the equivalent of 165,000 flight cycles over those three years. The frame was moved to it's test fixture in late January and the past few months have been spent installing instrumentation and other test fixtures.

Max Kingsley-Jones: Boeing targets 787 fatigue test buffer over lead aircraft

On the production front, the first painted 787 for Japan Airlines made its debut on the Everett ramp. The aircraft is LN 20 (ZA 175) and is in spot 106. There are 12 787s on the Everett ramp including one in the "circus tent" undergoing side of body modifications. There should be line move later this weekend to make room for the 25th 787 to be built, the first for Air India. Parts for this aircraft have already started arriving into Everett. ZA006 first flight has been put back to sometime in August though I don't have atarget date as of yet.

Lastly, the 787 test flight fleet exceeded 1,100 flight hours flown. ZA005 flew the flight that achieved that milestone. Thus far the test flight fleet has flown almost 36% of the required test flight hours.

Update to 787 test flight fleet status

I got a little update on the 787 flight test status.

The quick and dirty is that airplanes will be back in the air very soon.

ZA005 should fly again very soon, probably tomorrow. ZA004 can return to the skies as early as Saturday July 3rd and ZA002 should fly again around July 9th. Both ZA001 and ZA003 will return to the air on July 12th. This plan does give Boeing room to do any rework on the horizontal stabilizers as well as conduct post rework inspections and certify ready to resume flight testing.

787 Flight Tests on temporary hiatus?

Ok I'm still trying to find out more information but we all know that ZA001, ZA004 and ZA004 are in planned layups. ZA003 probably has to have rework done on its horizontal stabilizer not to say that the other 3 aircraft don't need it, they may but if they do need rework it can be done while they're in layup.

This brings us to ZA002 since it seems like the only 787 that is not in a pre-planned layup and doesn't have the horizontal stabilizer issue. The thing is that this airplane hasn't flown in a couple of days. Well I found out that this airplane is getting additional instrumentation for hot weather testing and that this testing will go remote (not flown out of Boeing Field but maybe Arizona, New Mexico or California). ZA002 should return to flight around July 9.

Lastly, Boeing is still planning to send ZA003 to Farnborough but with the current rework needed to be done on this 787, it might be a little tight in terms of schedule. Boeing plans to send the aircraft there on July 17th and leave around July 20th. Boeing has not definitively decided to send ZA003 to England and all depends on the progress of the rework and the results of the post rework inspections that would need to confirm that the rework has solved the problem and the aircraft is safe to fly.

Boeing Complete Firm Configuration of 787-9

Boeing Photos
UPDATE: A source has told me that Boeing has planned a tentative roll out date for the first 787-9 for February 2012.
In a press release this morning, Boeing confirmed that they have finalized the 787-9 configuration which will allow Boeing and partner engineers to begin detail design work and release those plans for manufacture of parts.

The 787-9 is the stretch version of the 787-8 though they are keeping the same wing as the 787-8 thus allowing for weight savings. The 787-9 is looking at a range of about 8000 nm to 8500 nm though that is said to be improving as Boeing is finding ways to save weight in the 787-9 (some of these design changes are planned to be incorporated into the 787-8 at later stages). The aircraft should seat about 250 to 290 passengers. The follwoing article by Saj Ahmad goeing into a nice analysis of the 787-9:

On the 9 by Saj Ahmad

Boeing is planning to have the 787-9 compete head on with the A350-800 (as well as the A300-300) but sources have told me that they feel that the 787-9 would be extremely competitive against the A350-900 which will be Airbus' first A350 off to be delivered. Right now both the A350-900 and the 787-9 are planned for first delivery in 2013 though some sources are telling me to expect further delays to the A350. If the 787-9 can meet or even exceed weight expectations as well as getting SFC (specific fuel consumption) improvements from both engines, then the 787-9 can be a true economic engine for many of the airlines that order it.

Here's video and a report Boeing put out about the 787-9 this morning:

Boeing Finalizes Configuration for Newest Dreamliner

Here's the test of Boeing's press release for the 787-9 configuration:

Boeing Completes Firm Configuration of 787-9 Dreamliner

EVERETT, Wash., July 1 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) today announced the completion of firm configuration for the 787-9 Dreamliner. Boeing reached this milestone after years of collaboration with airline customers and partners to determine the optimal configuration for the new stretch version of the Dreamliner.

"Firm configuration means the airplane's structural, propulsion and systems architectures are defined and not changing," said Mark Jenks, vice president of 787-9 development, Boeing Commercial Airplanes.

Boeing has completed the trade studies required to finalize the airplane's overall capability and basic design, allowing the airplane manufacturer and its suppliers to begin detailed design of parts, assemblies and other systems for the 787-9. As detailed designs are completed and released, production can begin. The first 787-9 delivery is scheduled for late 2013.

"We have a disciplined process in place to ensure we have completed all of the requirements for the development stage of the program," said Scott Fancher, vice president and general manager of the 787 program, Boeing Commercial Airplanes. "The team has done a fantastic job to get us through this important milestone."

The 787-9 is the second member of the 787 family. A slightly bigger version of the 787-8, the airplane will seat 250-290 passengers, 16 percent more than the 787-8. The 787-9 will have a range of 8,000 to 8,500 nautical miles (14,800 to 15,750 km).

"We have been working closely with our customers for years to reach this milestone," said Mark Jenks, vice president of 787-9 development. "We are excited about the performance and capability this airplane will offer our customers."

The 787 Dreamliner is an all-new twinjet designed to meet the needs of airlines around the world in providing nonstop service between midsize cities with new levels of efficiency. The airplane will bring improved levels of comfort to passengers with larger windows, bigger baggage bins and advances in the cabin environment, including lower cabin altitude, higher humidity and cleaner air. Delivery of the first 787 is planned for the fourth quarter of 2010.