Boeing moves 787s around, final assembly activities temporarily stopped

Boeing has temporarily stopped final assembly activities on 3 787 in order that 3 other 787s that have completed the side of body modifications are finished.

In doing so, Boeing has towed ZA151 (LN19) to a spot on the Boeing flightline and took ZA175 (LN 20) and ZA 176 (LN 21) went into temporary storage at the ATS Hangar. In their place Boeing put ZA100 (LN 7) in building 40-26 position 4, ZA101 (LN 8) in position 3 and ZA102 (LN 9) in position 2. These planes all have undergone the side of body modifications. It is anticipated that these airplanes will be in 40-26 for a little bit more than a month. When Boeing is ready to resume production ZA100 will be moved to 40-24 (767 final assembly line) and the line will pulsed so that ZA177 (LN 23) can start final assembly. The two of the three booted airplanes will return to the assembly hall once the reassembly activities are completed on the three early build production airplanes. ZA151 will go to the paint hangar soon and ZA175 and ZA176 will return to 40-26 once the reassembly activities are completed.

In other news, ZA005 may finally light the GEnx-1B engines today. I'll post if that happens.

787s on the move

According to Matt Cawby's blog, Dreamliner 2 (ZA002, LN2) has apparently completed it's side of body modifications and will be moved out of the temporary hangar on the Everett flightline.

In it's place Dreamliner 4 (ZA004, LN4) will be moved from the ATS hangar where it currently resides into the temporary hangar on the flightline for the modification work.. Dreamliner 1 (ZA001, LN 1) conducted VHF and HF radio checks but no word on when it will be pulled out of the paint hangar.

Since Boeing indicated that the modifications on ZA002 and ZY997 (static test) were to be completed within days, it does stand to reason that Boeing should be able to conduct the wing stress test on ZY997 within the next few weeks since I do believe the mods should be done on that aircraft too.

With Dreamliner 2 moving out onto to the flightline, Boeing will have the following 787s outside:
Dreamliner 2, Dreamliner 6, Dreamliner 7 and Dreamliner 8.

At last report Dreamliner 3 and Dreamliner 4 are at the ATS hangar and Dreamliner 5 is in building 40-24 (767 final assembly line). ZY998 (fatigue test) I believe is also in 40-24.

Matt Cawby's Blog

Flightblogger: Boeing complete 787 detailed design of 787 fix

Flightblogger is reporting tonight that Boeing has completed the detail design and computer validation of the last few final parts that makes up the 787 side of body join reinforcement fix. These final parts are being fabricated and should be delivered soon to be installed on the static test air frame as well as the test flight aircraft that are currently undergoing the installation of the modification.

Flightblogger is indicating that given that Boeing has finished the detailed design and computer validation of the fix that they have overcome the load issues that were discovered last Spring. Flightblogger is saying the test results received thus far are looking good.

Flightblogger

In other 787 news, Fleetbuzzeditorial.com came out with some great pictures of the 787 final assembly line:

Fleetbuzzeditorial.com - ZA100 and ZA101 at Everett

Additionally, Fleetbuzzeditorial.com also put out an interesting piece about the 2nd assembly line for the 787. This line is going to be crucial for Boeing to meet it delivery obligations. Here the article addresses the issues of the 2nd line, the choice ahead for Boeing and the pitfalls facing Boeing.

Second Guessing 787 Second Line

Lastly, the LCF's continue to make regular runs between the 787 suppliers and Everett. The nose section , wings, main fuselage, horizontal and vertical stabilizers for airplane 12 (LN 12) are already in Everett and I do believe the rear fuselage section is also in there though I have no confirmation. There should have been a line move already or will happen soon so that LN 8 (2nd production aircraft) will be moved out of building 40-26 thus clearing the way for airplane 12 to start final assembly in the coming days. Thus far Boeing is looking to maintain a 1 airplane/month production rate and gradually ramping that up to 10/month by the end of 2012. LN 7, the first production 787 is already outdoor on the Boeing flightline sans the Roll Royce Trent 1000s:

ZA100

Flightblogger 787 Update

Well now that we've reached the end of the third quarter, Flightblogger Jon Ostrower has but up a 787 update reviewing some of the happenings in the 787 program. Here's a bulleted synopsis:

• James Albaugh visited Boeing Charleston. There is talk of Boeing applying for permits to start clearing land for the 2nd assembly line facility. This comes right on top of Washington's State proposal to Boeing to keep the 2nd line in Everett. Also there seems to be some surveying and construction equipment at the Charleston site.
• Flightblogger made a correction regarding when the first 787-9 while be produced. Earlier he said it would be the 109th airframe to come off the line (LN 109). It will actually be the 139th airframe according to the latest production schedule.
• Well the 787 backlog is shrinking but because customers are cancelling. The latest is TUI which cancelled 10 787-8 but took purchase rights on 13 air frames. Whoop Dee Doo. Flightblogger also lists out the threats to the 787 backlog from other airlines considering cancelling their orders. It's a very dangerous time for the 787. They need to get it the air real soon.
• Production - Dreamliner 11 sections should all be in be earlier next week allowing the 787 line to move forward. The wings for Dreamliner 12 will be bought in early next week and ZA100 (LN7) will be moved out to the paint hangar to get an aqueous wash and paint job. It will not have the side of body fix installed. That will be done later but there is access to the areas of the wing and fuselage in order to install the fix. Dreamliner 11 will start final assembly later next week.

Flightblogger 787 News

Flightblogger: Fix installation to start next week

Flightblogger is citing program sources as saying that Boeing will start installing the side of body reinforcement fix for ZY997 and ZA001 next week. The fix should take about a month to complete meaning that ZA001 should reemerge from the Boeing paint hangar around mid to late October. Modifying each aircraft takes about three months but that time includes the time needed to prep each aircraft to receive the modification and to remove the necessary panels and gain access to the areas where the work crews will install the parts. The actual parts installation should take about a month.

ZY997 is receiving the fix concurrently with ZA001 will undergo the same wing stress test that had revealed the problem in the first place. This is to ensure that the modifications work as modelled on Boeing's 787 FEM. Once the fix is validated then ZA001 should be cleared to undertake high speed taxi tests and rejected take off tests prior to first flight.

Lastly, Flightblogger says that Boeing is about to start final assembly on ZA104 (LN10) which is the 4th production 787. The 787 line in building 40-26 should pulse today clearing the way for ZA104 to be moved into position 1 on the assembly line. That means that ZA100 will be in position 4, ZA101 will be moved to position 3 and ZA102 will be moved to position 2.

Look for the other test flight 787s to also have the modification installed in them over the next couple of months. Timing is still yet unknown.

Flightblogger: 787 fix installation to start next week

Flightblogger: Where in the world are the 787s?

Flightblogger posted a great article today showing how close Boeing is to starting the installation of the side of body fix on several of the test flight 787s.

In his post, Flightblogger detailed the locations of the 6 test 787s plus the static and fatigue frames and the 3 production frames. Here's a synopsis of the locations of these airplanes:
ZY997 - building 40-23 - all prepped for installation of fix, awaiting parts installation
ZY998 - Boeing Everett flightline
ZA001 (LN1) - paint hangar 45-04 - all prepped for installation of fix, awaiting parts installation
ZA002 (LN2) - temporary hangar on Boeing flight- prepping for side of body fix
ZA003 (LN3) - building 40-24 (767 line)
ZA004 (LN4) - ATS hangar - prepping for side of body fix
ZA005 (LN5) - building 40-24 (767 line)
ZA006 (LN6) - stored on Boeing Everett flightline to be towed to ATS hangar to be prepped for side of body fix
ZA100 (LN7) - building 40-26 position 3
ZA101 (LN8) - building 40-26 position 2
ZA102 (LN9) - building 40-26 position 1

Additionally ZA104 (LN10) has some parts already in building 40-26. There should be line move occurring very soon which allow the reaming parts to be flown in and final assembly start on this aircraft.

Getting Oriented: Where's the 787 fleet? Part Two

Also some great stuff from Randy Tinseth at Boeing:

Mod Squad

Undercover Airplane

Boeing Announces the start of final assembly on ZA100

Boeing has confirmed my earlier post from yesterday that ZA100, the 7th 787 to be built and the first production 787 for ANA has started final assembly. Here is Boeing's press release:

News Release Issued: June 17, 2009 6:32 PM EDT
Final Assembly Begins on First Boeing 787 Dreamliner for ANA
EVERETT, Wash., June 17 /PRNewswire-FirstCall/ -- Final assembly has begun on the first Boeing (NYSE: BA) 787 Dreamliner destined for delivery to launch customer ANA (All Nippon Airways) of Japan.

ANA and Boeing launched the 787 program with a firm order for 50 of the all-new composite jetliner. Deliveries are scheduled to begin in the first quarter of 2010.
Boeing and ANA celebrated the occasion with a traditional "Kagami wari" ceremony, the breaking open of a wooden "Taru" (sake barrel) lid with wooden mallets.
"This is a great day for the 787 team," said Scott Fancher, vice president and general manager of the 787 Dreamliner program. "In 2004, ANA demonstrated great faith in Boeing and the 787 by placing the largest launch order for any new airplane in Boeing history. Since then, the ANA team has been an integral part of developing the 787 family of airplanes.
"Speaking for our entire global 787 team, including our partners, I'd like to say we are honored by ANA's commitment to the Dreamliner," Fancher said. "We look forward to our continued partnership as we prepare the 787 to enter commercial service."
"Congratulations to Boeing on the start of the historic assembly of the first 787 Dreamliner for commercial flight," said ANA President & CEO Shinichiro Ito. "As the launch customer, we are delighted and excited to see the achievement of this milestone and to have worked closely together to reach this day. We look forward to the start of the 787 flight test program and delivery into our fleet next year."
The 787 Dreamliner has 865 orders from 56 airlines, making it the fastest-selling all-new jetliner in aviation history.
Pictured from left to right are: Kinichiro Suetsugu, manager - ANA U.S. Engineering; Takeo Kikuchi, general manager - ANA U.S. Engineering; Scott Fancher, vice president and general manager - 787 program and Mike Fleming, director of Services and Support - 787 program.
More information: http://www.boeing.com/commercial/787family/
Neg. K64723
Contact:
Mary Hanson
787 Communications
+1-206-898-4749
mary.hanson@boeing.com
SOURCE: Boeing
Web site: http://www.boeing.com/

787 Update from Paris, Day 2

UPDATE (06/16/2009; 10:50PM EST): A source has told me that final assembly on ZA100, the first 787 for ANA will start tonight in Everett.

Wow lots of news coming out about the 787 today so where to start?

Let's start with ZA001's road to first flight. I got a lot of the information from Guy Norris two 787 reports today.

Pat Shanahan gave an update on the status of Boeing's Commercial Product Development today in Paris. In the briefing he indicated that first flight could be a lot closer than the end of the month. Currently ZA001 is undergoing engineering tests that should lead up to a flight readiness review and then to final gauntlet which would after the review. Pat Shanahan also warned that there is no margin left in the testing and certification schedule so if there are problems that are uncovered during flight testing then that moves the entry into service to the right. Pat Shanahan also said that Global Aeronautica continues to be the weak link in the supply chain with the main issues being the travelled work as well as incorporation of the design changes.

So far ZA001 has completed flight control checks on June 16th and today are going through hydraulic systems checks today. Additionally, ZA002 which was rolled out to the flightline on Sunday has already completed its first fueling tests.

Guy's 29th 787 Update
Guy's 30th 787 Update
Aviation Week - ZA002 roll out

Highlighting the readiness of ZA001 to fly, Scott Carson told Bloomberg that ZA001could fly today if they wanted to. They won't fly it of course until they have gone through further tests but this illustrates the confidence that Boeing has in the 787 and the maturity of the systems that are loaded on the aircraft. He stated that the aircraft did much better than anticipated during the recently completed gauntlet tests.

Bloomberg's 787 article

From Flightglobal, Jon Ostrower confirmed what I had suspected a few days ago...the LCF flew in the main fuselage section for ZA100. This is the first production aircraft for ANA and was apparently delivered with a banner that read "Building with pride, the first 787 for ANA." The wings for this aircraft has been moved into position and should be soon followed by the three fuselage sections according to Jon.

Jon's Article

However, not all the news from Paris was positive for the 787. Qatar Airways is upset over the delays and Boeing's treatment of them. He threatened to pull the 60 plane order for the 787 if Boeing doesn't start to address their concerns. My opinion...Akbar Al Baker, Qatar Airway's CEO has been more impartial to Airbus thus he would always see Boeing in a harsher light. I consider him a wind bag who has to say outrageous things in order for him to stay relevant but unfortunately for a Boeing, he is someone that they would have to take seriously if they want to preserve their order.

Flight's Qatar Airways 787 story

Matt Cawby: ZA002 to the fuel dock late Sunday night

Matt Cawby has said that Dreamliner 2 (ZA002) should be at the fuel dock late Sunday night. It is also possible that the main fuselage section for ZA100 is being flown into Everett tonight as well as the LCF is on it's way to Everett from Charleston.

All this and the progress of ZA001 before the start of the Paris Air Show would give Boeing a lot to talk about during the press briefings on Monday and Tuesday.

ZA001 intermediate gauntlet testing entering the final stages

Both Flightblogger and Guy Norris report that ZA001 is entering the final stages of it's intermediate gauntlet testing with no apparent issues thus far. The stage seems to be setting for the final gauntlet followed by taxi tests.

Both Guy and Jon are reporting that Boeing is on block 14 and block 15 which covers environmental controls and more common core systems (CCS) testing today. On Thursday will see electrical systems tests, as well as pilot conditions tests and a final CCS test which will go into early Friday morning.

ZA002 is progressing through it's factory gauntlet and should be out by the fuel dock to go through the similar fueling tests that ZA001.

Additionally, Jon is reporting that the main fuselage section for ZA100, the first production aircraft for ANA, is being kept at Charleston, SC to finish off work and to ensure that there isn't any travelled work.

Flightblogger June 3rd Report
Guy's 23rd 787 Report

Here's a video from Liz Matzelle of Dreamliner 1 undergoing gauntlet tests on the Boeing ramp:

Simulated Dreamliner Test Flights from Liz Matzelle on Vimeo.

787 News - May 28,2009

Not too much to report except:

1) Boeing booked 5 orders from an unidentified customer for the 787. No word on which type (-8 or -9) though that will probably be revealed in a couple of weeks when Boeing releases its monthly order and deliviery numbers. Interestingly Boeing also booked a cancellation of 5 767s at the same time so I wonder if the cancellation has anything to do with the order for 5 airplanes? The only airlines that have the 767 on order (passenger version) are ANA, JAL and Lan. These carriers also have already placed orders for the 787 as well.

2) The LCF is on its way to Everett this morning from Charleston. It might be carrying the main fuselage section for ZA100 though we'll know a little later today.

No word on the start of intermediate gauntlet testing yet.

Guy Norris: Intermediate Gauntlet May Start On May 28th.

UPDATE: The LCF did fly in the forward fuselage section for ZA100 (the first production 787 for ANA). All that's left is the main fuselage section and final assembly can start on this airplane.

Some news on the schedule for the 787 first flight. Guy Norris is saying that intermediate gauntlet could start as early as this Thursday (May 28th) but it seems that Boeing may still be finalizing the final content of the intermediate. Guy reported that a final pre-intermediate gauntlet test meeting has been pushed back until tomorrow from today.

Also Matt Cawby is reporting on his web site that ZA001 has undergone VHF/RF radio checks until about 2 PM Monday afternoon when they closed down for the Memorial Day holiday. Additionally, Matt reported that the APU was tested twice, once on right common motor controller starter and the other time on the electric motor pump circuit. Matt also said that full gear swing tests were conducted while the aircraft was in the air mode.

Guy's Report
Matt's Report

Finally, it looks like the LCF might be flying in the nose section for ZA100 this afternoon.

Flightblogger: No gas yet and other musing.

Some real good information came from Jon Ostrower today regarding the progress of the 787 program.

Jon was able to post that Dreamliner 1 has not yet started fueling tests but that final checks are being done prior to the start of those tests.

Dreamliner 2 will be painted in ANA colors ('m wondering about the other 4 test airplanes now) and will be going back to the factory (building 40-24) around the middle of he month. It'll be super cool to se a Dreamliner is a customer livery!

Dreamliner 5 will have its GEnx engines hung soon. the engines were delivered last Friday. I saw a picture that Jon had posted showing Dreamliner 4, at the time without its engines but with a Trent 1000 behind the aircraft. I opining that those Trents are now hanging off Dreamliner 4 by now.

There should be a line move coming very soon allowing for Dreamliner 7 (ZA100) to begin final assembly once the two remaining fuselage sections arrive into Everett.

Jon's May 5th 787 Update.

More 787 movement

When it rains, it pours...I've been using that comment more often in the last few weeks for many reasons. The reason today in this posting is because Dreamliner 2 (ZA002) has left building 40-26 yesterday and made its way to the same paint hangar that Dreamliner 1 had until recently had occupied.

It's getting its paint job though I'm not sure what paint scheme it'll be painted in. There is also no word on where it will go after the paint job...it could go to the flight line, building 40-24 (767 line) or even back to 40-26. It will have to go through the same set of gauntlet tests that Dreamliner 1 is going through.

This also opens up a spot on the 787 (assuming it doesn't go back to 40-26) for Dreamliner 7 (ZA100). It's not known if Dreamliner 4 through 6 have move down one spot on the line or not though I do think that the last two sections for ZA100 should be in soon.

Charles Concklin is gracious enough to allow me to link to his pictures of Dreamliner 2 being rolled to the paint hangar.

ZA002 pic 1

ZA002 pic 2

ZA002 pic 3

ZA002 pic 4

ZA002 pic 5

ZA002 pic 6

ZA002 pic 7

Flightblogger: Factory gauntlet begins at 6:30AM PT on April 20th

UPDATE (April 20, 2009, 3:16PM): Boeing has confirmed to Flightblogger that the factory gauntlet has indeed started and should finish by tomorrow morning. An external computer has been hooked up to Dreamliner 1 to test how the airplane "flies." Read Jon's post here.


According to Jon Ostrower, ZA001 will start the first of three gauntlet tests this morning at around 6:30 AM PT. It is expected that this gauntlet should be done by early morning on April 21st thus paving the way for ZA001 to be moved to the flightline.

Jon also confirmed that the flight test wiring is mostly connected and all the external panels have been reinstalled.

Boeing is also getting an accurate measurement of the 787 OEW (operating empty weight) by removing the ballast and weighing the aircraft. It's not known what the result was but it is widely expected to be over the contractual weight.

Jon also reported that the rear fuselage section that was just delivered for ZA100 (Dreamliner 7) was 96% complete. Read Jon's post here.

As I reported on this blog earlier, it is expected that all traveled work in the 787 program will be eliminated starting with Dreamliner 8 (ZA101).

Lastly, Matt Cawby on his photoblog reported that Dreamliner 1 completed engine and APU fire protection systems tests in both the ground and air modes. See Matt's posting here.

Guy Norris: 787 factory gauntlet to start on April 20th

UPDATE, 9:05 PM, Sunday April 18, 2009: The LCF arrived today in Everett delivering the first fuselage section (rear fuselage sections 47/48) from ZA100, the first production standard 787. Matt Cawby got a great picture of the section being offloaded the LCF at Paine Field. Click HERE to see the picture.

According to Guy Norris at Aviation Week, the factory gauntlet test is planned to start on April 20th and should finish in the early morning of April 21st. The final software system integration test was passed on April 17th allowing for Dreamliner 1 to proceed with the start of the final systems checkout (on Sunday April 19th) and on to the start of factory gauntlet on the 20th. Guy reported that Dreamliner 1 will be put through 2 set of test during factory gauntlet each lasting 10 hours each.

Also on tap is the testing of the flight test instrumentation system that is on baord the 787 and will be recording all the test parameters during the flight test program. Major systems checkout is also being performed as well as inspection of the flight control surfaces and checking the trim on those surfaces as well as the doors and panels.

In my estimation, Dreamliner 1 can be out on the flight line as early as April 22nd which also happens to be the day that Boeing reports 1st quarter earnings. There will be an earning conference call during which I expect some general news about the 787 schedule to be revealed by Jim MeNerney.

Read Guy's posting here.

Flightblogger: Still waiting for gauntlet testing to start

Jon Ostrower is reporting that the factory gauntlet, widely expected to have started by now, has not yet started. It may start by the end of this week. As a consequence, the rollout of Dreamliner 1 probably won't occur until the end of April now.

Also the wings for LN 7 (now ZA100 as Boeing changed the internal designation of the production standard aircraft) have arrived into Everett last night and the rear fuselage should be in by the end of this week. Dreamliner 7 will be the first 787 delivered to launch customer ANA. I suspect that it'll take a month for this airplane to get outside to the flightline because of the three airplanes (ZA004, ZA005, and ZA006) that will be in front of it. Matt Cawby got a great picture of the wings being offloaded the LCF at Everett. Click here for the picture. Click here for Jon's post.

LN 2 and Beyond: The Impact to Certification

I just got confirmation that LN 2 (ZA002) most likely won't make it's first flight until the summer of 2009. The reason is due to a lot of traveled work yet to be done on the airplane and the shifting of resources to finish LN 1. All that along with the fastener issues have impacted LN 2 shop completion date.

This can slow down the certification efforts by Boeing for the 787.

However after airplane 2 is completed the pace assembly will pick up due to the more complete states of the follow on aircraft delivered into Everett. LN 3 should be done about a month after LN 2 and LN 4 not too long after that as it was delivered mostly complete and with very little traveled work.

It is projected that LN 7 should be 98% complete by the time it arrives in Everett and LN 8 should be shop complete when those sections arrive in Everett for preintergration.

The question now is how will LN 2's first flight in the late summer impact on the certification and EIS of the 787?