Production and Delivery

The 787 flight test program is going well, so well that Wall Street Analyst, in a survey, said that they believe that the 787 will be delivered on time by the end of the 3rd quarter, though many believe that end of July, 3 months from now, will see the delivery of the first 787 to ANA.

Susanna Ray: Boeing’s Delays on 787 May End as Analysts See On-Time Entry

To that end Boeing announced this afternoon that the first 10 pilots from ANA have arrived in Seattle to start training in Boeing's simulators (why they didn't go to the Boeing 787 training center in Tokyo is unknown).

Boeing Begins 787 Dreamliner Pilot Training with Launch Customer ANA

Start of 787 flight training marks significant milestone toward first delivery

SEATTLE, April 26, 2011 /PRNewswire/ -- Boeing (NYSE: BA) has started 787 Dreamliner pilot training with launch customer ANA (All Nippon Airways). Ten pilots from ANA began the training program with classroom instructions in Tokyo earlier this month. Training on simulation devices began April 23 at the Boeing Flight Services training campus in Seattle, Wash. First delivery of the 787 is scheduled for the third quarter of this year.

"The start of customer training is an exciting milestone on any new airplane program," said Sherry Carbary, vice president, Boeing Flight Services. "In the case of the 787 Dreamliner, we're seeing the results of a special working relationship between Boeing and ANA. We worked side by side with ANA for more than four years conducting simulator evaluations, curriculum reviews and cross-training so that each team learned from the other. It has truly been a collaboration between committed individuals dedicated to ensuring success," Carbary said.

The Boeing 787 flight training program uses an innovative suite of training devices including a full-flight simulator, flight training device and desktop simulation station to ensure that pilots are ready to fly the Dreamliner.

With the 787 pilot training courses, pilots can transition to the new airplane in five to 20 days, depending on pilot experience. Boeing 777 pilots can qualify to fly the 787 in as little as five days, given the high level of commonality between the two airplane types.

"This is a significant milestone for our company," said Hideyuki Shibuichi, senior vice president of Flight Operations for ANA. "Getting our pilots trained and prepared is essential to being ready to take delivery of the airplane later this year."

In order to bring training closer to customers around the world, Boeing has installed a network of eight 787 training suites at five global campuses: Seattle, Singapore, Tokyo, London Gatwick and Shanghai.

This clearly shows the confidence that Boeing and ANA have in meeting the first delivery of the 787 in a few months time. What is unclear is deliveries of the 787s that are in the process of being re-worked and have the required changes incorporated into them. Dominic Gates published a damaging article that puts into doubt Boeing's ability to delivery up to 20 787s this year with one engineer calling the change incorporation and re-work "a mess." Of the major tasks that are taking long to complete is the removal of sealants from the wings and resealing them. Apparently this process is taking weeks and requires gutting the aircraft. The computerized inventory system that Boeing is using in the program is also causing trouble and extending out the re-work schedule on the planes.

Read more of Dominic's article:

Dominic Gates : Boeing Still Struggling with the 787

Right now modifications are on going in building 40-24 (former 767 assembly line), ATS Hangar 3 and in Boeing San Antonio, Tx. facility. There are two 787 (both for Royal Air Maroc) in 40-24, 5 at ATS and the one JAL 787 in San Antonio. The problem is so severe that Flightblogger is reporting that JAL's first 78 which was supposed to be delivered in October of this year may be pushed out to November or December depending on which source you believe from Flightblogger's article. It does point to trouble on the horizon with getting these airplanes prepared for delivery and EIS.

Fllightblogger : The arrival of JAL's first 787 prompts a tangle of delivery dates

In an earlier post Flightblogger described the work that is on going within the ATS Hangar 3 and also reports that Boeing will be there for some time to come (looks like ATS will be making out handsomely from this). Boeing is so entrenched there that the Hangar has been dubbed "Boeing South." There are 5 spots at this hangar and currently Boeing has 5 787s, all for ANA, occupying all 5 spots within the hangar undergoing rework:

Spot 1: LN 9, ZA102
Spot 2A: LN 31, ZA117
Spot 2B: LN 7, ZA100
Spot 3: LN 24, ZA116
Spot 4: LN 8, ZA101

According to Flightblogger, ZA102 (which should have been completed this month) is due to finish rework by middle of May though it is unknown about the other aircraft.

Flightblogger: A tale of two factories: Boeing set to expand
787 mod operation

Guy Norris also has put out an update on both 787 and 747-8I testing thus far (RC021 the 2nd 747-8I flew for the first time today). In his article he reports that ZA001 was testing failure scenarios and back up systems certification testing. ZA001 is expected to continue with this testing extending it to fuel vent systems and controlability limits with a simulated engine out.

ZA002 will start certification testing on the package "A" EIS standard Trent 1000 engine.

Guy Norris: 747-8 and 787 flight test update

Finally, ZA004 which was to have started the switch to the improved Trent 1000 engines last week apparently will start the conversion process on April 27th (tomorrow). It is currently flying from Yuma MCAS back to Boeing Field. I am assuming that the engine change out will occur at Boeing Field.