Boeing Charleston to undergo FAA audit while production heats up. January 787 deliveries look to come in low.

UPDATE: The FAA sent out this response to the audit:  "The FAA will conduct a regularly-scheduled audit of the Boeing Commercial Aircraft production system in February. Boeing’s North Charleston, SC facility will be included in the audit. Five FAA inspectors will assess that Boeing’s systems are in compliance with the regulations for the manufacture of airplanes."


UPDATE:  Boeing emailed me this response:  "This routine audit, conducted about every two years at multiple Boeing locations, is part of Boeing maintaining our Production Certificate 700.  It’s not focused solely on Boeing South Carolina."


FAA Audit at Boeing Charleston

Sources revealed that Boeing Charleston will be undergoing an extensive audit, possibly one of the largest in Boeing's history, as the FAA examines Boeing's production practices.  Among the items that the FAA will be examining will be tool accountability, lost or missing tools, calibration dates, mismatched tools/tooling kits among others.  There will be 5 inspectors who will be at Charleston starting January 27th and remaining there until February 14th.  They will be looking over the shoulders of the manufacturing techs (MT) at the Charleston plant and will be quizzing them about the processes that they are using and how those specs and engineering were authorized.  It was revealed by the Wall Street Journal that Boeing is adding 300 contract workers and may increase that number to as many as 1,000.





Sources described the production of the mid body fuselage section built in building 88-20 as "a complete disaster, a cluster fuck."  This is a very worrying development to Charleston workers as some of them feel that the FAA may shut them down because of issues the audit may uncover.  88-20 is clearly the weakest link in Boeing 787 production chain as it is this unit that produces the mid bodies for all 787s whether they are built in Everett or Charleston.  Some MTs from the final assembly line in 88-30 have been sent to 88-20 to help reduce the strain that this area is facing.  Boeing has promised its MTs an 8% bonus if they can get the 16,000 jobs that they are behind on down to 8,000 by the end of February. If the issues in 88-20 worsen it could lead to slow down of 787 production and deliveries at least for this year.  This is not the first time that the South Carolina plant had undergone an audit.  In June 2008 the FAA audited the 88-20 plant which was then under the 50/50 joint venture between Boeing and Alenia Aeronautica of Italy known as Global Aeronautica.  The audit uncovered lax manufacturing standards and forced a 24 hour shut down of the plant to go over proper procedures regarding FoD.


I have reached out the FAA and Boeing Charleston for comment.  The FAA will inquire and get back to me.  I will update this post if I hear back from either party.





Meanwhile 787s continue to be built...



The FAA audit notwithstanding, Boeing continues to build 787s at both plants at a rate of 10/month.  This month Everett will have started assembly on 9 Dreamliners and Charleston would have started final assembly on 2 aircraft.  Boeing has rolled out quite a few unpainted 787s over the last few weeks onto the flightline.  Usually they go straight to paint after being rolled out.  I'm not sure why they changed this though Boeing test flight could be doing some ground testing before the aircraft is painted.  Whether the 10/month rate can be sustained due to the production issues in Charleston, particularly the mid body assembly in 88-20 remains unclear though this is why Boeing has bought in the contract workers.



Boeing did rollout the first 787 to be produced at the 10/month rate though they said that the aircraft is L/N 155 (ZA564) which is a 787 for ILFC being leased to Aeromexico.  Back in November when Boeing announced that they had started production on the first 787 at 10/month (through Randy Tinseth's Blog) they did not identified the aircraft that had the distinction of being built at that rate.  I was able to identify the aircraft as L/N 152 (ZA188) for Japan Airlines which sources told me was loaded into the first position and started final assembly on Nov. 14, 2013.  When asked about the apparent discrepancy, a Boeing spokesperson insisted that the aircraft that was loaded on Nov. 14th was L/N 155 not L/N 152.  I stand by my belief that the aircraft that kicked of the 10/month production rate is L/N 152.



First deliveries in 2014



Boeing has already delivered 1 787 this month to ANA and is in the process of delivering United's 9th 787 on Jan. 27th. I was expecting quite a few more by now to be handed over.  ZA469 (LN 129, A7-BCH) for Qatar Airways spent a long time being painted (and repainted), first in Ft. Worth, then at Boeing's paint facility in Portland, OR.  I assumed that it was now ready to finish production flight tests and be handed over to the customer but it has been hauled back inside 88-30 in Charleston for unknown reasons.  There are several more Qatar Airways 787s waiting to fly and to be painted but are sitting on the flightline at Boeing Charleston.  It appears that Boeing will not deliver any 787s to Qatar Airways this month.  They are trying to get a couple more to ANA as well as to the first BBJ customer - the Saudi Finance Ministry.  I also believe Boeing can deliver one to ILFC which will leased as a business jet to Sky Blue Holdings.  Boeing may be able to deliver one (maybe 2) to Air India as ZA230 (LN 25, VT-ANA) has been conduction flights as of late. ZA231 (LN 26, VT-ANB) conducted flight tests last month but none this month.  I'm not sure if  ZA231 is ready to be delivered. A very real reason for the slower deliveries is the weather in Everett probably played havoc with the flight tests as Everett suffered from several days of foggy conditions.  There were no test flights for quite a few days as the fog lingered around Paine Field.






Full 787 List

Current 787 Production List

Delivered 787 List

787 Monthly Delivery Tracking

787 Customer Delivery

787-9 Flight Test Hours

Current 787 Operators





 

Belated 787 Round Up

Boy I did pick a helluva day to come back and start posting.

First to start the day Boeing decided to buy out Alenia North America's share of Global Aeronautica thereby bringing the entire North Charleston facility into Boeing complete control. It is important to note that Alenia, the Japanese heavies, and Spirit still have responsibility in manufacturing their respective segments but the integration of section manufactured in Italy and Japan will be wholly done by Boeing. Here's Boeing's Press Release:

Boeing Acquires Alenia North America's Interest in Global Aeronautica

SEATTLE, Dec. 22 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) said today it has acquired Alenia North America's half of Global Aeronautica, LLC, a South Carolina fuselage subassembly facility for Boeing's 787 Dreamliner, and is now the sole owner of that entity. Alenia North America is a subsidiary of Italy's Alenia Aeronautica, a Finmeccanica company.

Operationally, Boeing will integrate the Global Aeronautica facility with the rest of Boeing's organization in North Charleston, S.C.

"The Boeing Charleston site is critical to the success of the 787 program," said Jim Albaugh, president and CEO of Boeing Commercial Airplanes. "Through this acquisition, Boeing benefits by joining together two solid operations - including their talented employees and state-of-the-art facilities - into one Boeing team. Ultimately, we believe integration of the site will increase productivity for the 787 program and allow us to maintain our long-term competitiveness."

"We are proud of the major contribution we have made over the past four years through our partnership in Global Aeronautica to the 787 program and to the state of South Carolina," said Giuseppe Giordo, president and CEO of Alenia North America. "We are confident that the foundation we have developed will continue to flourish as it is integrated into Boeing Charleston." The acquisition was effected through a wholly owned subsidiary of Boeing; other terms were not disclosed.

"We look forward to integrating the employees of both operations into one team in
North Charleston, along with continuing our partnership with Alenia on the 787 program," said Albaugh.

Global Aeronautica, LLC, began in 2004 when Alenia North America and Vought Aircraft Industries formed a 50/50 joint venture in support of the Boeing 787 Dreamliner. In 2008, Boeing purchased Vought's interest in Global Aeronautica, making the company a 50/50 joint venture between Alenia North America and Boeing.

Global Aeronautica's integration entails the joining of the mid-fuselage sections, the installation and testing of associated elements, and the application of surface finishes to more than 60 percent of the 787's fuselage. Global Aeronautica sits adjacent to the Boeing Charleston site and shares a 240-acre (97-hectare) campus.

So does this come as a surprise? Frankly no in my opinion. The Global Aeronautica production was key to getting the supply chain up and running smoothly. There are still issues with travelled work coming form Global Aeronautica so if Boeing hopes to ramp up to 10 or more per month then they have to fix the issues at GA.

Now the other big story is that ZA002 the second 787 made its first flight today as I had posted earlier, this airplane was expected to make it's first flight prior to Christmas and it has. This flight was cut short (it was in the air for about 2 hours) due to issues with the main landing gear doors, the nose gear and one of the two T-33 chase planes having run low of fuel.

Here's Boeing's statement of Dreamliner 2 taking to the air:

Second Boeing 787 Dreamliner Completes First Flight

EVERETT, Wash., Dec. 22 /PRNewswire-FirstCall/ -- The second Boeing (NYSE: BA) 787 Dreamliner, ZA002, completed its first flight today. The all-new airplane, which features the livery of the Dreamliner's launch customer, ANA (All Nippon Airways) of Japan, took off from Paine Field in Everett, completed a two-hour flight and landed at Boeing Field in Seattle.

"We are delighted that the second Dreamliner is in the livery of our launch customer, ANA," said Scott Fancher, vice president and general manager of the 787 program. "We are honored by the airline's support and look forward to delivering ANA the first production airplane next year."

Captain Randy Neville was at the controls for the flight, with Chief Pilot Mike Carriker operating as co-pilot. Neville and Carriker took the airplane to an altitude of 13,000 feet (3,962 m) and an airspeed of 200 knots, or about 230 miles (370 km) per hour. The airplane took off at 9:09 a.m. PST and landed at 11:10 a.m. PST.

This is the second of six 787s being used in the airplane's flight-test program. Each of the airplanes will be used for a specific set of tests, with this airplane focusing on systems performance. Like its predecessor, ZA001, the airplane is powered by two Rolls-Royce Trent 1000 engines.

"We would like to convey our sincere congratulations to the Boeing team for its achievement of this milestone, and we look forward to the delivery into our fleet next year," said Shinichiro Ito, president and CEO of ANA.

Boeing Press Release makes no mention of any in flight anomalies

Dominic Gates of the Seattle Times reports the gear door problem as well as issues with the nose gears that were eventually resolved. Dreamliner 2 apparently landed with the landing gear doors down instead of the up or stowed position. Here's Dominic's story:

First Flight of Glitches for Dreamliner 2

Flightblogger also weighed in with information on the Dreamliner 2's first flight and gave some clarity to the situation but all in all the issues that this airplane faced are minor and will be corrected and tested before the airplane goes up again.

Flightblogger: Explanation and Clarification of ZA002's Landing Gear

Guy Norris also had posted on the Things With Wings blog more details on the systems experienced issues on ZA002 during yesterday's flight.

First Flight Problems for 787 Show Up on ZA002

Lastly, here are some great videos. The first on is ZA002's take off as filmed by Matt Cawby (Thanks to Matt on the video)

The second video is landing of ZA002 at Boeing Field. Notice the gear doors in the open position as the aircraft is landing.



Here's a second view of ZA002's first flight from the Future of FLight

Boeing Announces Charleston, SC Groundbreaking

Boeing Image

Well now it's underway. Can't wait to see the first 787 rolling out in about 18 months or so

Boeing Breaks Ground on Second 787 Assembly Line in North Charleston, SC

Boeing facility expands production capability and increases footprint in South Carolina

NORTH CHARLESTON, S.C., Nov. 20 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) today held a groundbreaking ceremony to mark the start of construction for the second final assembly site for the 787 Dreamliner program at its Boeing Charleston facility. The facility also will have the capability to support the testing and delivery of airplanes.

"Today's event marks the beginning of an expansion plan that will strengthen the 787 program and allow us to continue building on the footprint we have established in South Carolina with Boeing Charleston and Global Aeronautica," said Jim Albaugh, president and CEO of Boeing Commercial Airplanes. "Locating the second line in North Charleston will allow Boeing to successfully compete in the aerospace market and grow for the long-term benefit of many stakeholders."

Today's groundbreaking ceremony was attended by Albaugh; South Carolina Gov. Mark Sanford; Sen. Lindsey Graham; Sen. Jim DeMint; Rep. Henry Brown; Rep. James Clyburn; State Sen. Hugh Leatherman; State Sen. Glenn McConnell; State Rep., Speaker of the House Bobby Harrell; Charleston County Council Chairman Teddie Pryor, Sr.; North Charleston Mayor Keith Summey and other key officials from South Carolina. Anita Zucker, chairperson and CEO of The InterTech Group, Inc., served as master of ceremonies for the event.

Boeing Charleston performs fabrication, assembly and systems installation for the 787 aft fuselage sections. Global Aeronautica, which is 50 percent owned by Boeing, is responsible for joining and integrating 787 fuselage sections from other structural partners.

"We look forward to expanding our capability in South Carolina through our existing site, while maintaining our commitment to the Puget Sound region where Boeing Commercial Airplanes remains headquartered," said Albaugh. "Puget Sound will continue to design and produce airplanes, including the 787."

The 787 Dreamliner will be more efficient, quieter and have lower emissions than other airplanes while offering passengers greater comfort and the convenience of direct, nonstop flights between more cities around the world. Fifty-five customers around the world have ordered 840 787s since the program was launched in April 2004, making the Dreamliner the fastest-selling new commercial jetliner in history. The 787 family of airplanes will carry 210 to 330 passengers on flights up to 8,500 nautical miles (15,750 km).

Charleston Ground Breaking on Nov. 20th

Mike Mecham at Aviation Week posted on "Things With Wings" blog that Boeing will have the ground breaking ceremony for the Charleston final assembly line next Friday, Nov. 20th. The construction is expected to take about a year and a half and should allow Boeing to produce its first 787 by early 2012.

One interesting detail in his report is that there will be two buildings and the paint shop will be located within the building that also houses the final assembly line as oppose to Boeing Everett set up where all aircraft produced there must be towed across a bridge to the other side of a highway to the paint hangars.

The second building will house the delivery center, storage facility and probably offices.

Mike Mecham : Charleston Welcome

Boeing decision on 2nd 787 line may be imminent

Flightblogger and various other news sources are reporting that talks between Boeing and IAM have broken down. This may lead to Boeing to decide to locate the 787 2nd assembly line in North Charleston, SC.

Yesterday, the South Carolina State Senate passed a package of incentives to lure Boeing to North Charleston for the 2nd 787 line. It now appears that those incentives along with the breakdown of talks between Boeing and the IAM will lead to Boeing making an announcement that they will locate the 2nd assembly line in North Charleston. Boeing has already purchased land in the area as well as filed the necessary permits for construction of the assembly hall located next to Global Aeronautica and Boeing Charleston. Boeing said that those actions were necessary for planning purposes.

Now Washington State politicos are not giving up. Senator Patty Murray from Washington has requested that representatives from IAM 751 and Boeing meet at her Washington State offices in order to try and agree to a no strike deal. It seems that IAM has agreed to it but there has yet been no word from Boeing to Sen. Murray's invitation.

It may be that Boeing has already made up its mind. We'll soon know.

Flightblogger: 787 Line Saga

Bloomberg: Boeing, Union urged to meet in 787 talks

787 production continuing

Well after a restful (somewhat) Labor Day weekend here's some 787 news. Production is continuing on production standard aircraft and now there is more room in 40-26 to build those production aircraft. ZA004 is due to move out soon if it has been moved out already from the final assembly line to hangar space that Boeing has leased from ATS at Paine Field. ATS is Aviation Technical Services and does heavy checks and other maintenance services to airlines and cargo operators. I think Boeing would put two of the 787s in the ATS hangars in order to perform the side of body fix without effecting current production of the 787. ZA006 should be moving out later this week either to the flight line or to another hangar spot (not sure if it would be a Boeing or ATS hangar). Also of note is that some of the aircraft do not have their engines on. This is to make the installation of the modification easier though the engines are still on ZA002 and ZA004, they were not on ZA005 and ZA006.

This would leave Boeing with three 787 in production at their final assembly line in Everett: ZA100 (LN7) in position 3, ZA101 (LN8) in position 2 and ZA102 (LN9) in position 1. Some parts for ZA104 (LN10) such as the wings and tail section have already arrived but when all the parts are delivered, that airplane will be quickly moved into position 1.

Boeing's LCFs have been busy conducting flights across the supply chain. Now some of these flight could be training flights and/or repositioning of shipping fixtures but undoubtedly there is also some movement of the fuselage sections between suppliers in Europe and Japan and GA in Charleston, SC.

Boeing is "weeks away" from issuing a new schedule; Preparing test fleet for fix

According the Chris Musoke, Boeing's 787 chief engineer, they're weeks away from issuing a new schedule for first flight and delivery of the 787. He was speaking at the meeting of the Organization of Black Airline Pilots in Atlanta.

As proof that there is progress towards testing and implementing a fix on the side of body join, Flightblogger says that ZA001 has been moved inside to prepare for installation of the parts and that ZY997, the static test airframe, has scaffolding surrounding the aircraft in preparation of installation and testing of the fix. The parts needed have already been manufactured and shipped to Boeing for ZY997 and ZA001. If this fix does the trick, the parts will be manufactured and installed in all the other aircraft in the supply pipeline as well as those already assembled.

Access to the areas to be fixed will be very tight and will require technicians to get to the areas through an access door into the center fuel tank and several access holes. The first two flight ready 787, ZA001 and ZA002 have already have had these areas closed out and cleaned for testing which means that they would probably have to go though a close out procedure again and have the tanks washed out. The other four airplanes won't have that issue but this should be all minor compared to the problem that has to be fixed.

Flightblogger also reports that assembly activities are continuing on production standard 787 though some assembly activities will be put on hold until the fix is verified and the parts are installed. Airplane 8 has already started final assembly and parts for airplane 9 will start arriving later this week starting with the wings. Also reported that starting with airplane 15, the fuselage part (section 11) of the fix will be installed at Global Aeronautica in Charleston with the wing box part (section 12) of the fix being installed at Everett when the fuselage and wing box are joined in final assembly.

Flightblogger also reported that ZA004 has completed gear swing tests inside building 40-26. ZA003 is probably still inside the 747 assembly building and either ZA005 or ZA006 is outside on the flightline.

Flightblogger: Prepartations start for wing-body fix

Editorial: 7/7/09: A good day for the 787

Two year ago Boeing rolled out the 787 on 7/8/07 in a huge media event emceed by Tom Brokaw. Boeing was very proud of what they had accomplished to that point. The two years that followed was not something they wanted to crow about. Neither was the announcement in late June about another delay to the 787 that heard collective groans from airline executives, Wall Street, shareholders, Boeing employees and aviation enthusiasts around the world waiting for this plane to finally soar.


This last delay seemed more insulting, the cherry on the top of all the other delays (that's optimistic being after the cherry you can't add another layer) since it came so close to first flight and only a week after Scott Carson pronounced his confidence that ZA001 would fly by June 20, 2009. It was like Boeing was the gang that couldn't shoot straight. However the public perception, people have to understand that designing, building and testing airplanes, especially one with as much new cutting edge technology that the 787 has, is no easy feat.

Yesterday was a good day for the 787 program coming two years after rollout. It was a good day for two reasons:

1) The 787 finally moved on its own power in a series of low speed taxi tests which included low speed RTO (rejected takeoff) tests. These tests continued into Tuesday evening around 10 PM. These taxi tests followed the successful conclusion of final gauntlet testing which concluded on the evening of July 2nd before the 4th of July weekend. You can read Boeing's discussion of the final gauntlet testing here.



2) By far the biggest news and, in my opinion, the best news came from Charleston, SC when Boeing and Vought announced the sale of Vought's 787 work share and assets to Boeing. This makes Boeing more responsible for the fabrication and integration of 787 assemblies compared to what they originally envisioned in 2003 when they launched the 787 program. A lot of the 787 program is experimental and new. This not only includes the technology but the production system that Boeing had decided upon. Now this is where risk management comes in. Boeing's purchase of Vought's 787 unit and their purchase of Vought's share of Global Aeronautica is an exercise in risk management. They recognize the weakest link in their supply chain and in the end effected the necessary actions by which they could more directly control the situation. To be clear, Vought had made great improvements at the facility in Charleston as demonstrated by improved build quality and greater completion (less traveled work) of the 787 rear fuselage being sent to Everett. However, where the risk lay was in Vought's precarious financial situation and doubts about them being able to effectively and efficiently ramp up production. Vought had its doubts, Boeing had it doubts and the result was today's announcement.


Today's action by Boeing demonstrates that Boeing will not let this program fail. The projected costs of purchasing Vought's 787 site is estimated to be about $1 billion ($580 million paid to them directly plus the release of Vought from repaying advances that Boeing had given Vought for its 787 work). Clearly this kind of cash outlay represents Boeing determination to make the 787 program the cornerstone of the company for the foreseeable future. They cannot let this program fail. Now some will point to the assumption of Vought's 787 operations as proof positive that the 787 production model of outsourcing and systems integration is drastically flawed. Boeing purchase of Vought's share of Global Aeronautica is another example of Boeing proactive risk management.


But then how can they explain that other suppliers are doing well within this new production framework? MHI, FHI and KHI continue to build and deliver their work packages and are reducing traveled work. Spirit has been the brightest spot amongst the supplier partners with no more traveled work in the forward fuselage sections that are sent to Everett. And Alenia which had some quality problems very early on is performing very well. This indicates that, after the teething problems and the learning curve ramp up, Boeing's supplier partners are doing well and is vindicating the production model for the 787. Boeing did fail initially in overestimating the capabilities of the supplier base to quickly design test and build the composite structures and other breakthrough technologies for this aircraft and this is what put them in the hole. They had redeploy assets to get the supply base back in line thus from a risk management perspective the reacted accordingly and I believe they will continue to do so. I don’t think they’ll bring in more of the manufacturing work in house save for Global Aeronautica if they don’t show substantial progress ahead of the production ramp up.

Lastly, there continues to be speculation if this move will lead to the 2nd production line (it’s a matter of when not if) being located anywhere but Everett. (Scott Hamilton wrote a piece yesterday regarding the 2nd line). There is a lot of compelling arguments for locating the 2nd line Charleston which has been wrote about ad nauseum and thus I won't repeat it here but I do beleive that Boeing will decide later this year to locate the 2nd line in Charleston for the those reasons. Once the 2nd line is established and producing 787s, Boeing 787 backlog would be eased considerably, though that will all depend on the supplier's ability to produce enough throughput to supply both lines at the same time. If successful, it all started with Boeing taking control of the situation in Charleston with Vought.

Flightblogger: Boeing to buy Vought's 787 Operations

Flightblogger got a major scoop today by saying that Vought (owned by the Carlyle Group) has agreed to sell Boeing the 787 operations in Charleston, SC where the rear fuselage section is constructed. Now this deal has not been made public but will be done so in a short amount of time. Jon said that sources have indicated that this acquisition can give Boeing the momentum to start a 2nd 787 production line in Charleston which has been hinted at in the past and should allow them to get production running to 10/month by 2012 according to Boeing's plans.
This deal will bring Boeing back into a much more involved role as manufacturer of the 787 then their initial plans when the program was launched in 2003.

With this Boeing would not be directly responsible for the manufacture and integration of the complete rear fuselage section (47/48) as well as the vertical stabilizer (tail). They're also heavily involved in Global Aeronautica, owning a 50% stake in that venture which they also purchased from Vought.

Now if Boeing decides (as I believe they will) to start a 2nd line in Charleston, one issue people are going to bring up is the lack of skilled aeronautical workers in the area. It should be noted that when Boeing started the 787 final assembly line in Everett many of the MT (manufacturing techs) were new hires who did not have direct aerospace manufacturing experience but who had skill sets that would be of use on the final assembly line after undergoing an intensive period of training and testing before being hired to work on the 787 final assembly line. I do think that Boeing will set up a similar education and training facility to train 787 MTs in South Carolina for the 2nd assembly line similar to what they did for the 787 line in Everett.

Boeing buys Vought 787 facility

Boeing Looking More Seriously at 2nd 787 Final Asembly Line

In an interview with reporters Mike Mecham, Guy Norris and Jens Flottau, Boeing CEO Jim McNerney gave the strongest indication that Boeing will go ahead with a 2nd production line for the 787. According to the Aviation Week article the decision may come as early as late this year with an year of starting operations in late 2010 when work on the 787-9 will be expected to get underway.

Aviation Week cites sources as saying that the second line announcement can come very soon and that North Charleston, SC has been chosen as the sight of the 2nd final assembly line. North Charleston does have the advantage of being nonunion as well as the locale for current 787 assembly activities done by Global Aeronautica (main fuselage integration) and Vought (rear fuselage fabrication and integration) as well established logistics capabilities and plenty of land to build a final assembly building near the current Vought and GA facilities. Boeing would have to only fly in the forward fuselage from Wichita and the wings from Japan (not counting the structures from Alenia in Italy and the structures from Fuji and Kawasaki in Japan that will go into the GA site as it currently does).

Predictably the Boeing Unions in Everett (SPEEA and IAM 751) are not happy at the prospect and they may have even more reason to worry in my opinion. If Boeing goes ahead with a South Carolina assembly plant, they could add enough space at that plant to possibly shift all 787 final assembly from Everett and there would be nothing that IAM or SPEEA could do about it especially if the new final assembly line is more efficient than the Everett line.

Aviation Week's 787 Second Line Article

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

787 Update from Paris (and beyond)

UPDATE: ZA002 (N787EX) is out on at the Boeing fuel dock. Matt Cawby posted a photograph this morning showing the aircraft finally outside and ready to conduct fueling tests. First flight of ZA002 should take place by July 21st. Matt Cawby's Photo.

Well Boeing gave some more information into when the Dreamliner will finally leave the ground through it was hardly earth shattering news. First the first flight was not going to be event driven (ie not fly during the air show) but rather fly when it's ready to fly. This has been Boeing's mantra since August 2007.

Secondly, Scott Carson did say that it'll fly on June 30th which is the end of the 2nd quarter. Again not earth shattering news from Boeing. Jon Ostrower did post that it is possible that the schedule can be bought forward from June 30th, he cited program sources.

Now according to Jon's post (also from program sources), the way things are laid out over the next two weeks are as follow:

Now until through this weekend: preps for final gauntlet testing
Early next week: final gauntlet testing (about 2 days in length)
Middle of next week to the end of the week (June 25 or 26th): Inspections of 787 prior to start of taxi tests
Late next week through the weekend of June 27th-28th): taxi tests (787 moves under it's own power)
June 3oth: In the air

Now this is a zero margin schedule and as Jon said, it could move to the left depending on how further testing goes.

Jon also reported that Boeing and the partners in the supply chain agreed that all travelled work would be eliminated by airplane 14 which should be in final assembly by the end of this year. Alenia North America chief Giuseppe Giordo also said in Paris that it still takes Global Aeronautica about 300 days to finish the main fuselage section of the 787 but they are working on reducing that number. This probably accounts for all the sections flowing into the GA assembly sight in Charleston.
Guy Norris also put out an update on the 787 this morning. The first flight fuel verification testing that was supposed to take place today was actually completed on Sunday thus allowing for Boeing to proceed to the testing of the flight control system today (June 15th) with a focus on the tail and full deflection testing of the horizontal stabilizers (tail feathers). Guy also said that a few tests were completed on ZA002 in advance of it being rolled out of the hanger and to the fuel dock. According to my information, that was to have happened last night but I have not received verification of that yet.

Jon's 787 Update from Paris
Guy's 28th 787 Update

787 line moved on Friday (March 13)

Boeing moved the 787 line on Friday March 13th.). Dreamliner 3 was moved out of the line to building 40-22 (747 line) where it will continue assembly thus moving Dreamliner 4 and Dreamliner 5 down one spot and making room for Dreamliner 6 to start final assembly on Monday March 16th in position 1. Dreamliner 2 will remain it is current spot in position 4 in building 40-26

The final section for that airplane, the main center fuselage is being flown tonight to Everett from Global Aeronautica on the Dreamlifter. Track the LCF flight here.

Near term 787 dates

I just got some new information on some near term 787 goals (near term, meaning over the next week). I got confirmation that the forward fuselage for Dreamliner 6 (ZA006) was delivered into Everett last night on the Dreamlifter. That leaves the main fuselage to be delivered. That part should arrive from Global Aeronautica in Charleston, SC on March 13th (this Friday).

The line move that was supposed to occur on March 8th is now slated to occur on March 14-15th.

After that the parts for Dreamliner 6 will be moved into position 1 on the 787 line around March 16th to start final assembly.

Lastly, AF-KLM has announced that they will decide between the 787 and the A350 by the end of 2009 or early 2010. If Airbus doesn't get GE to sign on to the A350 then the odds are in favor of the 787 getting the nod.

Dreamliner 5 to start final assembly soon?

Jon Ostrower is reporting on his blog that the rear fuselage section for Dreamliner 5 will be arriving this week. That only leaves the forward fuselage and the main fuselage sections to be delivered. I'm still trying to find out when those sections will be delivered.

Also Jon reported that the pieces for the main fuselage section for Dreamliner 9 have been delivered to Global Aeronautica this past weekend to start that section's assembly and systems integration process.

UPDATE (1/12/2009): Jon Ostrower reported on his blog here, that the aft fuselage for LN 5 has arrived in Everett and that it is 95% complete. It has it fasteners repalced. Jon things the remaining two sections should be in Everett by the end of the month to start final assembly.

Effects of the strike on the 787

About a week and a half ago a Boeing 747 LCF made a routine delivery flight from Nagoya, Japan to Charleston, SC stopping in Anchorage, Alaska to refuel. Now typically these delivery flight are routine and usually not the subject of a blog entry but with the IAM strike going on at Boeing, it does underscore a couple of things about the what is happening with Boeing’s production model and it’s relationship with outside contractors and its labor unions.

First let’s look at the 787 as of late last week. Jon Ostrower, reported in his blog that ZA001 had its nose cone attached and that the airplane is sitting on its wheels which means that the landing gear swing tests seem to have been completed. Jon also says that he saw flight test equipment on the airplane. Right now the impediment to Boeing getting the plane out the door (other than the strike) is getting the remaining flight test and cabin equipment installed on board as well as knock on effects from some small systems integration issues. Schedule margin is tight without the strike as it is and Jon and Scott Hamilton reported that first flight would be delayed as much as 5 weeks (into mid December at the latest) before any strike effects.

Adding to the pressure of the 787 program is a report by Geoffrey Thomas saying that the production problems on the 787 are hurting new sales of the airplane. Apparently, delivery slots are not available until 2020 which means that the impact of the production problems have effectively pushed out the earliest delivery slots by about 2 to 3 years unless Boeing can manage an orderly increase of 787 output to about 14/month.

Now because there is strike on doesn’t mean that work on the 787 has come to a grinding halt as evidenced by the LCF flights this week. The tier 1 contractors like Global Aeronautica, Vought and Mitsubishi will continue to produce their respective work packages for as long as they possibly can (without shipping further sections and wings to Everett). Depending on when the strike ends, this work during the strike period will eliminate traveled work going to Everett. Boeing can restart production on LN 5 when those parts arrive with no traveled work to be done thus utilizing the 787 production line in a manner it was intended. This can only help in increasing the production rate of the 787 in the near term. So while the strike is on going at Boeing that hasn’t completely bought the 787 production to a grinding halt and may in fact help the production system recover fully by the time the strike ends. One note to all this is that some Boeing’s 787 suppliers are starting to cut back on production, namely Spirit has said they are cutting back on production on some of the products they supply to Boeing without citing any specific Boeing programs. At the end of the day there will be progress in the suppliers’ efforts to clean up the production mess and get their end of the business back on track because of the strike. If Boeing can get its end in order then the production model for the 787 can be a big success.
Read an AP report here.

That all said the question that should be asked (and so far has not) is the IAM being very short sighted in its on the issue of outsourcing. James Bell Boeing’s CFO said at a conference yesterday:
The union, he said, "would like all of the work to be done in the Puget Sound area and that's not realistic." Boeing, he explained, would like "complete flexibility" to outsource work to suppliers; "We have to figure out what's the right balance."
There is nothing that could stop Boeing from selling its Renton and Everett plants to an investor thus turning Boeing into a pure systems integrator and having Renton and Everett bid on work packages much like other firms did when they went shopping for suppliers for the 787. We’ve already seen that happen with Boeing Wichita when those operations were sold to Onex Corp. and was renamed Spirit Aerosystems. Is something like that going to happen, probably no but it is plausible. It is one thing for the IAM to fight for better wages and health care benefits for their membership and their retirees but it is another thing to try and dictate to Boeing management what can be built where in a world of tight margins and intense price competition from Airbus. To see how much things have changed Spirit is going to be building fuselage panels for the A350 for Airbus. Clearly outsourcing is not just an American phenomenon but a global one and Boeing competes on a global stage.

787 production slow down

News out of Charleston, SC that Vought will temporarily stop producing the rear fuselage barrels for the 787 is the first indication that the bottleneck at Everett may not improve for a few months. An article in Charleston's Post and Courier News quotes Elmer Doty as saying that they do plan on resuming production of the rear fuselages later this year. It looks like Vought's line is as full as it can be especially since they're shipping only one complete rear fuselage section each month. Additionally, Spirit is also slowing its production of 787 forward fuselages.

The production issues and the travelled work all contributed to a bottleneck at Boeing's Everett's plant where scaffolding has to be put up around the air frames that have delivered thus far in order to finish all the travelled work. That as well as other issues has hindered Boeing from pulling out even one shop complete 787.

While the rest of the supply chain seems to be recovering, Boeing is still dealing with the issues left behind from the earlier issues thus the suppliers will have to slow down their production though it does seem that Global Aeronautica does have room and doesn't need to slow down their production of main fuselages.

This production slow down will allow Boeing to catch up with the rest of the supply chain as well as allow the tier one suppliers to ensure that all their respective work packages are appropraitely stuffed when shipped to Everett. However it will probably allow them to deliver only the 25 787 as they've indicated unless there is a significant improvement in the production rate (which would be necessitated by a steep learning curve on the 787 line). Once Boeing's 787 manufacturing technicians are fully up to speed on working on the 787 final assembly line as Boeing has intended (without any travelled work or any other engineering issues) then production can be ramped up to the 10/month or more.

Flightblogger 787 Update, part 2

Jon Ostrower continues his three part series this time updating us on the supply chain with particular emphasis on Global Aeronautica. GA seems to be the slowest cog in the wheel and it remains to be seen if they can sufficiently up the rates. It took them 11 months to send ouver the center section for Dreamliner 4 and it wasn't 100% complete but close.

They need to get up the learning curve and do it fast.

Read Jon's report here.

Boeing 787 Update at Farnborough

Pat Shanahan gave a 787 update this morning in the UK though short on details (as opposed to the one in April) it still suggests that they are on track for first flight late this year. Power on was successfully completed with a few minor glitches that were quickly resolved. Boeing is finalizing the shipping date of the two remaining sections for LN 4 later this week. My guess is that they will be in Everett by the end of next week but we’ll see.

Boeing is planning to activate LN 1’s hydraulic system next week, otherwise known as “oil” on (as opposed to power on). This will allow Boeing to raise and lower the landing gear in the hanger before first flight (you don’t want to test something like that on first flight in case something goes wrong). It will also allow Boeing to test all the movable flight surfaces (flaps, slats, elevator, rudder and speed brakes). As reported on this web site earlier, Boeing was planning to move the fatigue air frame from 40-24 to the fatigue test area and move LN 1 from 40-26 to 40-24. The later move is probably in doubt due to hydraulic on next week and the need to test some of the mechanical systems. I think the move of LN 1 probably won’t occur until 1st to 2nd week of August

Regarding LN 4 – the damage to the main fuselage caused a disruption in the schedule and the certification process maybe impacted though Boeing says they do have some schedule margin to absorb the disruption in the schedule.

Speaking of margin, Shanahan said that small glitches in the production schedule is eating up some of the margin. I’m presuming that he’s talking about LN 4 and that may be a cause for concern further down with certification testing. Everett is now the bottleneck for continuing production. The suppliers are no longer the issue and they have greatly improved on reducing traveled work. Look for no traveled work starting with LN 8, by then Global Aeronautica should be shipping 100% complete sections, Spirit is already shipping 100% complete sections with LN 4 and Vought will ship 100% complete rear fuselage sections starting with LN 5.

One issue with regards to the road to first flight is the traceability of the brake control software to meeting certification requirement which is being characterized as a minor issue and that a fix is being implemented. Crane Co. is responsible for that part of the Dreamliner.

Right now Boeing is saying that APU and engine testing is due to start next month, followed by gauntlet testing (a series of tests that trick the airplane’s computer into thinking that it’s in flight and see how the systems react to normal flight procedures as well as in flight anomalies). This will be followed by taxi and brake tests and then first flight. Shanahan is saying first flight should take place around November but I personally think it’ll be October if there are no major issues.

So far Boeing has completed 98% of safety of hardware testing, 96% of hardware is qualified for first flight (will be 100% by 2nd week of August) and 95% of hardware is ready for first flight. Despite this progress there is still some part shortages with LN 1 though these are minor. There is still some work to do in the mid fuselage and the wing of LN 1 and they need some tubing to complete the fuel system on the airplane as well. Also they need to complete airplane 2 before airplane 1 can fly as airplane 2 will be used for ground verification tests. Finishing up work in the mid fuselage of LN 2 also has eaten into some of the margin.

In terms of future variants, Boeing is planning to finish trade studies for the 787-9 by the end of the year and have a firm configuration for the 787-9 by the 2nd quarter of 2009 and entry into service by early 2012. They also said that the 787-3 will benefit from the experience gained on the 787-8 and 787-9 thus indicating that they are still going to go ahead with that variant though the time table is still up in the air.

On the static test aircraft frame, testing is due to start soon with three main tests to be done soon: pressurization testing, leading/trailing edge testing, and vibration testing.

Until the next update…have fun and keep your head in the clouds!

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.