UPDATE (10AM) ZA236 is flying back to Everett today. This is a strong indication that F&R/ETOPs testing is complete. The F&R/ETOPs certification testing for the GEnx-1B powered 787s was based out of Boeing Field. With the airplane heading back to Everett the testing appears complete and this airplane can be released in order to prepare it for delivery to Air India.
Boeing's efforts to complete 787 flight testing with the GEnx-1B engines are close to being completed if they aren't finish already. ZA236 has flown just under 153 flight test hours thus far. The aircraft needed to fly about 150 F&R/ETOPs flight hours to finish the certification program for this version of the 787. Boeing has not confirmed that they are finished with the tests as of yet. The true indication that they are complete is when ZA236 flies back to Everett to finish preparations for delivery to Air India.
As far getting other 787s ready for delivery, there are about 10 787 at the Everett Modification Center that are undergoing change incorporation or shim inspection in the rear fuselage as well as one airplane in 40-24. Three of these airplanes were aircraft that are close to being delivered (to Japan Airlines or ANA) including ZA177 (LN23, JA822J), ZA179 (LN33, JA225J) and ZA117 (LN42, JA806A). Once these airplanes are inspected and repaired (if needed) then they will continue they typical preparations for delivery. The list of 787s at EMC is below with the locations highlighted in green. These are the airplanes I anticipate will be the next few that will be delivered. Interestingly enough these include a few of the very early build airplanes, ZA100 (LN 7), ZA534 (LN 10), and ZA501 (LN 12).
Jim Albaugh, speaking in Singapore has said that up to 55 787s would have to be inspected and repaired for the flaw. To put it in proper context, this would include all the airframes from LN 4 to LN 59, the latter of which is currently in position 1 in 40-26 and just starting final assembly. This number also includes the 5 airframes that have already been delivered to ANA but does not include any airplanes sections that have yet to be delivered to Everett for final assembly.