Boeing Moves ZY998 to Fatigue Test Rig

Boeing Photo

Boeing announced, this morning, that it had moved the fatigue test air frame to the test rig at building 40-41. Here's Boeing's Press Release:

News Release Issued: February 2, 2010 9:16 AM EST

Boeing Moves 787 Dreamliner Fatigue Test Airframe to Testing Rig

EVERETT, Wash., Feb. 2 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) on Sunday moved the 787 Dreamliner fatigue test airframe to its structural test rig. The test rig is located in the northwest corner of the Everett, Wash., site.

Test set up is expected to begin immediately, with tests commencing midyear.

"Unlike static tests, where loads are applied to the airplane structure to simulate both normal operation and extreme flight conditions, fatigue testing is a much longer process that simulates up to three times the number of flight cycles an airplane is likely to experience during a lifetime of service," said Scott Fancher, 787 vice president and general manager, Commercial Airplanes. "This testing is instrumental in confirming the longevity of the airplane."

787 News

Boeing's production of 787 continues as the flight testing program is well underway. Boeing just started final assembly on the 16th airplane destined for LAN. LN 16 is also known as ZA531 (ZA530 is assigned to LN 10).

The current production and aircraft disposition list is below as well as at the bottom of the blog at all times:



Lastly, Flightblogger is reporting that ZA002 should be flying again around now and that ZA001 should be back in the air around Feb. 2, 2010 (Groundhog Day). Finally, ZY998, the fatigue test air frame is finally being moved to building 40-41 where it will go through 3 years of test to see how the air frame will fair over a life time of service.

Flightblogger: Pre-flight and layup: A 787 and 747 Round Up

747-8 still hasn't moved. At last report Boeing wanted to rerun some gauntlet tests. No word on how the retesting has gone or when taxi tests will begin.

787 Update - January 10, 2010

Yesterday another flight test 787 showed up on the Everett ramp being prepared for it's first flight. Sources tell me that this aircraft is ZA004 but a registration has not yet shown up on it's side.

ZA003 should show up very soon on the Everett ramp as well very soon to start it's preparations for first flight.

Both ZA003 and ZA004 are projected to have their first flights in the first week of February.

Additionally, Matt Cawby reported on his blog that the fatigue test air frame is very close to finishing its side of body modifications and should be moved to the fatigue test area around January 30th to start 3 years of fatigue testing. It will be moved out of the temporary hangar that is on the Boeing flight line.

Matt Cawby's January 9, 2010 Blog Update

Flightblogger got a great article up on the production challenges that the 787 still faces now that the aircraft has entered test flights. Thus far Boeing has completely assembled 1 complete 787s (LN 1 through LN 11) plus two test air frames (ZY997 and ZY998). Currently there are 4 aircraft undergoing final assembly (LN 12 through LN 15) and parts of LN 16 are just starting to arrive in Everett. Flightblogger is reporting that Boeing planes to start increasing production on the 787 round mid February.

Flightblogger: Dreamliner Production Challenges Lie Ahead

Finally through today, January 10, 2010, the 787 test fleet has accumulated over 45 and half hours test flight hours. Also today, Za001 flew the longest 787 test flight thus far at 5 hours and 48 minutes. You can track the 787 flight test hours by going to this spreadsheet here.

Boeing confirms completion of mods on static air frame and Dreamliner 2

Both Photos Courtesy of Boeing

This out from Boeing early (very) this morning:

Boeing Completes Side-of-Body Installations on Two More 787
Dreamliners

EVERETT, Wash., Nov. 16 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) has completed installing reinforcements within the side-of-body section of two more 787 Dreamliners.

Over the weekend, employees at Boeing's facility in Everett, Wash., finished reinforcing the full-scale static test airframe and the second Dreamliner designated for flight test. Installations were completed Nov. 11 on the first flight-test airplane.

The modification entails installing new fittings at 34 stringer locations within the joint where the wing is attached to the fuselage.

"Our focus now is on completing the static test later this month, which will validate the modification," said Scott Fancher, vice president and general manager of the 787 program. "Concurrently we are restoring the airplanes and completing the functional tests required to fly by the end of the year."

The static test airframe is being refitted with strain gauges and instrumentation required for testing. Access doors, systems, seals and fasteners removed from airplane No. 2 to provide access are being restored in preparation for continued testing on the airplane. The first 787 also is being restored.

Fancher said the program is on track to fly the 787 by the end of the year.

"We are building momentum with each milestone we achieve," Fancher said. "This team is focused on its goals and bringing us ever closer to first flight."

I'm assuming that Dreamliner 2 will finish up reassembly activities inside 40-24. Additionally, Matt Cawby is reporting that the fatigue test air frame and Dreamliner 2 (ZA002, LN2) will swap places with Dreamliner 2 going into building 40-24 and the fatigue test air frame taking its place on the flightline prior to undergoing modifications for the side of body join.

Matt Cawby's 787 Update

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

End of August and the 787 summertime blues

Well we're quickly approaching the end of August, the end of summer and hopefully the end of a period that Boeing would like to forget. If it weren't for the side of body issue the 787 would be flying around Boeing Field now for about two months. Now we have to wait about another three month for that happen (if Flightblogger is correct) and another month from now to hear Boeing's revised schedule. Too much is now riding on this for them to get it wrong. So with that in mind let's try and look ahead to what's yet to come.

As some of you may know, Boeing big wigs flew into Everett last week from Chicago and I believe the big topic of conversation was the 787. But I am hearing that Scott Carson might be retiring at the end of this year. Coincidence or not we'll see but right now it's just a rumor. I wonder if it's another coincidence that Boeing filed building permits today for the North Charleston site. Me thinks not! Boeing needs the second line to recover the lost ground in 787 production so the second line is inevitable (I said so a year ago) and I think Boeing will add additional autoclave capabilities to the 2nd line. The question will be where will the 2nd line go? At this point, if I'm a betting man it will be North Charleston but that will hinge on the vote by Boeing Charleston workers weather to decertify its union on Sept. 10th. If it is decertified then I think North Charleston is a shoo in despite what concessions Washington State and the IAM would give to Boeing. Boeing needs to have uninterrupted production if they are to catch up with deliveries. IAM going out on strike every 3 to 4 years will only get in the way of that.

Now articles are out that Air Berlin is considering cancelling it's order for 25 787-8s whether this is a bluff to wring out more concessions from Boeing is unclear though it sounds like Air Berlin is making an issue of the delays as a cornerstone of their arguments. That's a little surprising as they would be grateful for the delays as Air Berlin has a lot of capacity right now and they would probably need to add capacity in the future after the world economy recovers and air travel with it.

Now let's see what's happening on the tarmac at Everett. Well not too much there there is a big pup tent in the middle of the Boeing flight line where several of the 787 that will be in line for the fix will receive it. Out on the flight line there are 4 787s: LN2 (in ANA livery), ZY998 the fatigue air frame, LN6 and another test flight 787 in the Boeing 787 livery which I suspect may be LN 5. I think LN 4 is probably in 40-26 and LN 3 is still in 40-22 and LN 1 in the paint shop. That means that LN 7 and LN 8 probably have made or will make a line move soon to clear way to start final assembly on LN 9. The parts of this aircraft are in Everett.

Guy Norris also reported that tests are still going on on LN 2 on the Boeing flightline. He also has a great article on Boeing's moves in Charleston as well.

Guy's August 25 787 update
Guy's Boeing-Charleston Article
Air Berlin Mulls 787 Cancellation

Lastly, is Wall Street turning bullish on Boeing and specifically the 787? According to Scott Hamilton at Leeham & Co. a couple of Wall Street analyst now have a brighter outlook on the 787.

Scott's article on 787 forward loss.

Flightblogger: 787 preps for factory gauntlet

Jon Ostrower got another detail filled post out not too long ago. In it he confirmed what I posted with regards to the the factory gauntlet: factory gauntlet will start in about 10 days around April 10th) and should take 2 to 3 days after which it will be rolled out to the flightline.

The intermediate gauntlet will occur in mid-May soon after ZA002 (Dreamliner 2) joins ZA001 out on the flight line. while ZY998 the fatigue airframe will go back to the factory (though I'm not sure if it'll go to the 787 (40-26 building) line or the 767 line (40-24 building)) for continued structural re-work. My guess is it'll go to 40-24 so as not to interfere with 787 production.

ZY997 the fatigues test air frame is under going a quality assurance reconciliation before moving to the wing load limit test.

Read Jon's posting here.

Lastly, I found out that LN6 has completed wing body join.

ATW's Geoffrey Thomas gives update on 787

A great short article on where the 787 program is and it's immediate future. Here's a summary:

ZA002 - Fastener rework should be completed by this weekend and power on should be in about 10 days.
ZA003 and ZA004 - fastener rework is on going.
ZA005 - still in fuselage-wing join.
ZA006 - Wings arrived totally completed and painted. As reported here the tail feathers arrived last week (the horizontal stabilizers). Fuselage sections should arrive by Feb. 27th with no open issues when they arrive in Everett. The rear fuselage could arrive by the end of this week.
ZY997 (static test airframe) - fastener rework should be completed next week and wing load test will restart immediately. That should take about two months to perform.
ZY998 (fatigue test frame) - Should be turned over for the start of fatigue testing on June 1st.
Geoffrey also says that Boeing's internal target for first flight is the last week of April.

Read Geoffrey's article here.

Flightblogger: Dreamliner 1 through 6 Update

LN 1 in building 40-24 taken by Saj Ahmad 4 days ago.

Used with permission from Fleetbuzzeditorial.com

Jon Ostrower has posted a detailed update on 787 line numbers 1 through 6. Read it here.

Here's a summary:

LN 1 (Dreamliner 1): Set to be powered on again very soon. Will go through a "medium blow" pressurization test in early February. The engines nacelles cowlings have been reinstalled as well as the remaining control surfaces. As I reported earlier, Boeing has thrown a lot of resources at LN 1 and Boeing is leaving on some of the temporary fasteners for the duration of the testing program. This decision has saved a lot of time. Speaking of which the time frame for first flight looks to be shifting to the right a bit with some milestones now being classified as TBD. This includes first flight which was thought to be around the April 20th to April 24th time frame.

LN 2 (Dreamliner 2) : Dreamliner 2 had its engines and all flaps installed and work continues to center on finishing up fastener replacement. Jon is also reporting that power on should happen soon followed by the start of ground vibration testing in mid-March.

LN 3 (Dreamliner 3): Dreamliner 3 is on it's legs (landing gear) and has its engine pylons on.

LN 4 (Dreamliner 4): Dreamliner 4 is about to get its legs. This airplane, probably because it's in more complete shape, has a low priority in terms of resources.

LN 5 (Dreamliner 5): Dreamliner 5 is about to start final assembly. The main fuselage section is undergoing some traveled work installation prior to being sent into position 1 on the final assembly line. Section 41 arrived 100% complete and the rear fuselage arrived 95% complete. The pylons for the GEnx engines have been installed on the wings. This aircraft has arrived in a more complete state than the previous aircraft.

LN 6 (Dreamliner 6): The wings have come in and are virtually complete and have been painted as well.

ZY997 and ZY 998: The static and fatigue test airframes continue to have their fasteners replaced. for the static airframe this should be done by middle of February and thus set the stage for the resumption of static tests that are needed prior to first flight.

Flightblogger: 787 Update for 2009

Jon Ostrower has posted a great updates for the near term milestones that Boeing hopes to accomplish with the 787 on the road to first flight.

Please read it here.

Here is a summary:

Dreamliner 1 will leave the 787 final assembly bay in 40-26 and will go to a spot in the 767 final assembly building in 40-24. It will occupy a spot that the 787 fatigue test frame occupies. ZY998 will be towed to the Everett flight line where it will be completed and towed to the fatigue test area.

Dreamliner 1 will be in 40-24 for one month to finish up fastener replacement and minor assembly tasks. It will then start the first of three gauntlet tests. The first is the factory gauntlet where the flight test division puts the 787's systems through its paces.

After that Dreamliner 1 will go through the aqueous wash and the repainting as reported on this blog earlier in December.

By the end of March Dreamliner 1 will start the 2nd gauntlet test which is the starting of it's RR Trent 1000 engines for the very first time. The last guantlet is the running of all the 787 systems for 8 days straight to ensure that there aren't any issues.

Presumably, taxi test and RTO (rejected take off) tests will occur soon after the third gauntlet followed by first flight.

Dreamliner 2 is continuing fastener replacement which should be concluded by mid February. Then this aircraft will conduct ground vibrations testing presumably from late February to late March. There is still no word on when Dreamliner 2 will finish assembly and join the flight test program.

With the first 787 leaving the factory floor, this will now open up a spot in the final assembly hall for Dreamliner 5. The aft section of which will probably be delivered to Everett by the end of January. The wings, horizontal stab and vertical stab are all at Everett. The main fuselage section is being paced by the fastener replacement work that is on going. No word on the forward fuselage section but I presume that there is still on going fastener work with that airplane as well.

787 Schedule

In light of the 787 schedule push back that Boeing revealed earlier this month I was able to learn from sources of the immediate schedule going forward.

First the main news: Boeing is hoping to schedule first flight for sometime around late April 2009. My guess: April 20th.

Around Dec. 23 to December 28th of this year, Dreamliner 1, ZA001, will have an aqueous wash of the wing fuel tanks. This indicates that the wing build and the wing instrumentation is pretty much complete. The aqueous wash is to remove carbon shavings and other contaminants from the wing fuel tanks. It's not known if it has to be rolled out of the assembly building for this wash.
The fastener replacement on ZA001 should be completed by the end of December.

ZA002 should have it's fastener replacment done by mid February but it may not have its first flight until August of 2009. I have not yet found out why ZA002 is so far behind and it could put the entire certification schedule for the 787 into disarray.

ZA001 will leave building 40-26 (the final assembly building) for the paint shop around Feb. 24th to get a fresh coat of paint which should be done by March 2. After that ZA001 might go to 40-24 prior to going to the paint hanger though that has not been decided yet. ZA001 might be factory complete by Feb. 24th though there might be some traveled work taken out to the flight line.

Lastly, ZY998, the fatigue test air frame might be moved to the flight line prior to year end even though the build is not yet complete. No reason is known.

Farnbourough order rumor and other musings

On the eve of Farnborough I've been hearing rumblings of some 787 orders. These are unconfirmed rumors. Some are obvious but others are not. I heard that Ethiad, Asiana (amongst the obvious airlines), and Turkish Airlines (the unexpected order) maybe ordering the 787. While Boeing has over 60 unidentified orders including 2 large blocks of 23 and 35, it seems that a couple of these airlines may not be the ones who placed those orders. It seems for certain that the 787 will break 900 firm orders by the end of the show and I'm willing to say that a further order from ILFC, one of Boeing's most important and influential customers, will be given that honor. I will hope to confirm these potential orders soon.

While the 787 final assembly production has been stopped momentarily because of the issues with LN 4, the final assembly of the first three flight worthy aircraft continue. The engines for LN 1 will have been re-installed by the end of this weekend...a major step forward as Boeing was not expecting to re-install them until August....so they're several weeks ahead of that schedule. Jon Ostrower reported it here.

Look here at Matt Cawby's site for more pics. Here's a picture of the fatigue test frame in 40-24. This is another engine picture. And final picture also here. It is my understanding that LN 1 should be moving in about a week to 10 days from now but I'm not sure if this is on hold because of the issues with LN 4. Speaking of which we hope to have more clarity on that airplane by Tuesday.

LCFs on the move, possible delivery flights

UPDATE:

The Dreamlifter, reg. number N780BA took off today for Wichita
but soon after takeoff developed a problem with its flap and had to dump fuel
and return to Paine Field. They landed safely.

The 747 Large Cargo Freighters, or LCFs have been on the move. Yesterday one left for a flight to Nagoya. It is unclear if it going to be bringing in any parts but if it is it will bring parts for delivery to Global Aeronautica as Everett is still waiting for parts for Dreamliner 4. It could be returning transportation fixtures back to Nagoya and then fly back with parts for other 787s to be assembled at Global Aeronautica.

Today though a flight plan was filed for an LCF to to fly from Everett to McConnell AFB in Wichita, KS. This is where Spirit Aerosystems manufactures the forward fuselage for the 787. It can be flying there ostensibly to pick up the nose section.

The 3rd LCF is already in Charleston, probably waiting for Boeing's ok to load and deliver the main fuselage for Dreamliner 4 which had been the source of the hold up.

Speaking of Global Aeronautica, they had a 24 hour standdown to review FOD prodcedures. The FAA found violations but did not order the standdown. That order came from management. Given the recent news, this is probably a good idea. See the article from the Seattle Times here.

Finally, Matt Cawby has pictures of the fatigue test site on his web site. This is where the 787 fatigue test airframe will go to start 3 years worth of fatigue testing. Simply put they will simulate a lifetimes worth of flights over the period of three years and see how the airframe responds. Check out his pictures here.

Boeing moves 787 fatigue

ZY998 being moved to building 40-24.

Image Courtesy of Boeing

Yesterday Boeing moved the fatigues aircraft from building 40-26 to building 40-24 where it will stay for about a month finishing up some assembly tasks. Today LN 2 will move to position 3 while LN 3 will remain in position 1 until probably late this week.

As Jon Ostrower reported earlier, the third Dreamlifter, newly modified in Taiwan, will fly to the US in the next few days and immediately will be pressed into service to deliver the center fuselage for LN 4 (the fourth flying 787) late this week. The forward fuselage is also due to be flown into Everett soon and once those two sections have arrived then final assembly will immediately begin. LN 3 will probably move to position 2 late this week to make room for LN 4. The fatigues airframe is expected to move from 40-24 to the fatigue test area in about a month and at the same time LN 1 will move from 40-26 to 40-24 to finish up assembly tasks and prepare it for the move to the flight line. In doing so on or around July 21st, Boeing will make room for LN 5, the 5th test flight aircraft and the first to be fitted with the GEnx engines.

Here's is Boeing's press release here.

Flightblogger: 787 next steps

Jon Ostrower just posted an update for the 787 program now that powe ron has been completed. Click here to read his report he has a couple of great pictures. Here is a brief synopsis:

ZY998 to move to 40-24 this evening between 7 pm and 8:30 pm local time.

Power on went extremely well, in fact they expected problems that never materialized.

Gauntlet testing is up next - fooling major systems into thinking that the plane is flying and see how they react. This is a major test to see if the 787 is ready for flight.

With 998 moved out of the way LN 2 and LN 3 will each be moved down the line tomorrow. LN 2 to position 3 and LN 3 to position 2. This will allow the start of final assembly on LN 4.

Dreamlifter 3 will arrive in the US next week and will be tasked with delivering the center fuselage for LN 4. This will be done next week. The forward fuselage section for LN 4 will also be delivered next week.

Integration time for the center fuselage will be one third of what it is now by late summer (with the delivery of LN 6 to Everett). It is hoped that by LN 8 that there will be no more traveled work with the center fuselage. Integration of systems and wiring in the center fuselage will now start to drop after the center section for LN 4 is delivered.

First 787 Completes Power On

Image Courtesy of Boeing

Boeing continues to demonstrate that it's gotten the 787 program back on track. Today Boeing issued a press release announcing that the first 787 (ZA001) has completed the full power on process and now all of the 787s systems are powered on.

Now comes the additional tasks of making sure that all the systems are talking to one another as well as finishing the assembly tasks including loading up the final versions of the software and reattaching the engines.

Boeing will not roll out the 787 to the flight line until September 6th and first flight will not occur until very, very late in October.

Boeing accomplished the very important task 10 days early. They had previously said that power on will occur by June 30th and here they were able to accomplish it by June 20th. One has to wonder if the rest of Boeing schedule is going to be conservative? They will probably need any extra margin built in to the schedule to deal with any major issues. If all they encounter are minor ones then it is possible that the 787 schedule can be moved forward.

On a related note, a LCF flew into Everett last night from Wichita, presumably it was carrying section 41 (forward fuselage) for ZA004 though I haven't been able to confirm that. Boeing has said that they plan to start construction on ZA004 by June 30th and it was revealed on this blog that final assembly is due to start around June 21st though Boeing still doesn't have the center fuselage section for this plane yet from Global Aeronautica.

Also ZY998, the static test frame was scheduled to be moved yesterday but there was no sign of movement out of 40-26. It is possible that this move will occur this weekend thus pushing out the start of final assembly on ZA004 by a few days.

Edit: Jon Ostrower just told me that the LCF didn't bring in the forward fuselage for LN 4 and that section is not due to arrive until next week. Instead it had delivered the HTP (horizontal tail plane) for LN 5

787 Dates to Watch For

Hi all fellow 787 watchers (if there is such a thing). Well a liitle while after watching Tiger make a run for the US Open title (I'll be watch the playoff tomorrow...should be real exciting), I heard of a few dates concerning the 787 program and a few milestones to watch out for now that power on has started:

6/19 - ZY998 will move from building 40-26 to 40-24 (the 767 line) and at the same time LN 2 will move up one spot in 40-26 to position 3 and LN 3 will move to position 2. Because:

6/20 - Final assembly will start on LN 4. We do know from Jon Ostrower's report that section 41 for this airplane will arrive on 6/19. Presumably the main fuselage section will arrive on or before the 19th as well.

7/20 - ZY998 will move to the fatigue tes tare for the start of the 3 year long fatigue tests. At the same time LN 1 will move out of building 40-26 and into building 40-24. My guess for the move to 40-24 is to finish up small items do more power on testing and pre ground test testing (testing flying surfaces, landing gear retractions, etc) while still making room for LN 5. This may mark the last time this airplane in on the 787 final assembly line. ZA001 being moved out of 40-26 will make room for ZA 005 the first Dreamliner to be fitted with the GEnx engines.

7/21 - ZA005 (LN 5) will start final assembly in position one and LN 2, LN 3 and LN 4 will be moved up one position respectively.

9/6 - ZA001 will be considered "shop complete" and moved out to the flight line for the start of ground tests.

Late October 2008 - First flight of ZA001, the first 787.

These are further milestones to look at in order to judge Boeing's success with the revised program schedule.

787 Production moves ahead

In the last few days Boeing and it's partners have been providing the media with great access to the other partner sites in the US, specifically North Charleston where Vought builds section 47/48 (the rear fuselage) and Global Aeronautica (Boeing-Alenia venture) assembles the main fuselage; and Wichita where Spirit Aerostructures builds section 41 (forward fuselage).

Here Boeing and its partners are eager to show the progress at overcoming the production issues that have hobbled the 787 program..

For example, Jon Ostrower too this picture of the flight deck of Dreamliner 3 during the media day in Everett.

Now compare that to the picture of the flight deck of Dreamliner 4 which Jon has taken today and posted on his blog site. Section 41 for LN 4 is virtually 100% complete according to Jon and will be shipping to Everett on June 19th. This is also the same day that ZY998 the fatigue test frame is pulled out of building 40-26 at Everett and placed into 40-24 (767 line). Jon also said they Spirit is already building the section for LN 22.

This means no traveled work (or very small bits and pieces of traveled work at the most) for section 41. Now what about the other sections. Well it's expected that Global Aeronautica will be shipping 100% complete main fuselage sections starting with LN 8. I think this won't happen until September of this year. Vought, who had been the source of frustration for many at Boeing actually has com along extremely well and is expected to start shipping complete rear fusealge sections with LN 5 (the first GEnx powered 787). That probably won't happen until sometime next month. Reduction of all this traveled work is going to go a long way of validating Boeing 787 construction approach and will set them up to raise production rates. The wings are also arriving in substantially better condition though it not known how much traveled work come with them.

So starting with LN 8, it is possible that almost all if not 100% of traveled work can be eliminated.

When that happens is anyones guess though it is possible that as time goes on and there is more and more confidence in the supply chain Boeing can up the production rate in order to catch up deliveries as much as possible.

Soon after the 19th Boeing will start final assembly of LN 4 after LN 2 and LN 3 are moved down the line. Wants important at this stage is that workers currently working on LN 3 won't move with it but will stay at the first position to work on LN 4. This means that the final assembly line will start doing what it was designed to do.

787 getting close to power on.

BREAKING: Another source says that power on will officially start tomorrow - June 12th. I am trying to get more information.

A source in the 787 program told me that there is still some good progress being made on LN 1, the first 787. Power on should still take place at the end of this month.

More significantly, ZY998, the fatigue test airframe is due to move out of the final assembly building (40-26) on June 19th and into the 767 final assembly building (40-24). It'll stay there until July 20th when it will be moved to the fatigue test site north of Boeing assembly plant.

The move on June 19th will allow Boeing to start assembly on Dreamliner #4 (LN 4).

Jon Ostrower has been in Charleston yesterday and got some great pictures and reported on the progress at Vought and Global Aeronautica. Jon also reported that the third LCF (Dreamlifter) has been certified by the FAA and will be in the US to start hauling 787 sections and parts in July.

More news to note: Boeing and Vought closed on the sale of Vought's share of Global Aeronautica to Boeing today. Boeing and Alenia are now 50-50 partners in the joint venture which assembles the main fuselage section for the 787 from the sections supplied by the three Japanese Heavies and Alenia. In being a partner with Alenia, Boeing is essentially bought inside the Global Aeronautica plant where they can have more control and can continue to look over Vought's shoulder in Charleston.

Lastly,
Dominic Gates from the Seattle Times has a great article on a media visit to Charleston which took place yesterday. Read about it here.

More progress

We're only 4 days into June but there are signs of continued progress on the 787.

Jon Ostrower, in his blog, reported that Saudi Arabian Airlines has committed to 12 787s in a mixture of leased and purchased aircraft. This is supposed to be a firm contract though Boeing has not said anything as of yet. See Jon's report here.


Hamilton Sundstrand, who is manufacturing the power supply units for the 787 now has delivered "everything Boeing needs to turn the power on." David Hess, the President of Hamilton Sundstrand said "All the hardware and software that Boeing needs to power on is ready and in Seattle right now."

Pat Shanahan promised David Hess a huge meal if Hamilton Sundstrand delivered the power supply units on time. I hope Pat has enough funds to feed these guys!

The power supply units and the brake monitoring system were the only worries left. Now that the power supply is no longer an impediment to power on, it is looking more and more likely that power on can be achieved by the end of this month. I have heard rumors that there is still plenty on work left to be done on Dreamliner 1 and I've heard that Boeing may not even make the June 30th deadline. There is no specifics yet but even Pat Shanahan said that it would be a horse race to get power on by June 30th.

As to the brake monitor issue. That is not needed for power on but will be absolutely necessary before Boeing takes Dreamliner 1 outside to the ramp for the start of ground and taxi tests. No word on the resolution of that issue.

Last sign of progress, one of the 747 Dreamlifters left yesterday for Nagoya, Japan. rumor has it that it is picking up the wings for Dreamliner 4 to be delivered into Everett later this week. Also later this week, ZY998, the 787 fatigue test airframe is due to be pulled out of building 40-26 at Everett and moved to the fatigue test area north of the final assembly plant. With that move, Dreamliner 2 can move up to position 3 and Dreamliner 3 can move up to position 2 to continue final assembly. This will leave the MOAB at position 1 free to accept Dreamliner 4. Currently the horizontal tail plane and the vertical tail plane (fin/rudder) are the only major parts of Dreamliner 4 in at Everett. It looks like Boeing will meet it's deadline in getting ZY998 out and starting work on Dreamliner 4 prior to June 30th.