787 production update

UPDATE: Dominic Gates has article saying that the latest assembly pause is due to issxues at Alenia, again. No wonder James Albaugh is bringing 787-9 HTP production back in house. Read his article:

Dominic Gates: Boeing calls two week stop on 787 section deliveries to Everett

This past weekend I referred readers to Matt Cawby's web site which showed two 787 fuselage parts being loaded on the the LCF. Boeing has told me that due to high winds in the area, the parts were placed inside the aircraft so that they were out of the elements.

This must indicate that the back of 40-26 is pretty full with 787 parts since these sections could not be stored in the Boeing facilities at Everett.

Boeing has also said that they will tell 787 suppliers that they will have a slight pause in 787 parts shipments into Everett. The pause will average about 2 weeks depending on the supplier. Both suppliers as well as workers on the final assembly line will continue working on the aircraft as the pause only effects shipments into Everett. Here's Boeing's statement:

With regards to the sections being loaded onto the LCF:

We loaded those pieces back on because forecasters here predicted heavy winds and we didn’t want to have them sitting outside in those conditions. Nothing more.

With regards to the shipment pause:

We will formally notify partners in the days ahead that we are going to have a
slight (it’s different partner by partner but on average two weeks) pause in
shipments. As we said in summer, this is one way we will manage the production
system. Partners are continuing to work during this shipment pause as is the
final assembly team here in Everett.

Dreamliner 4 circuit around the country and potential 787 production woes resurfacing?

ZA004 undertook a very long 13+ hour test flight that took it around the country yesterday to test the 787s to test...of all things... the fuel gauge of the aircraft. According to Flightblogger, the test (which I initially thought was an ETOPs flight) was to see how the Fuel Quantity Indication System. The test added a large amount of flight test time to the 787/RR test flight fleet and bought them closer to the 2,430 flight hours needed to certify the 787/Trent 1000 engine combination and allow for deliveries to start to ANA. The Trent 1000 powered 787 test flight fleet has accumulated well over 1,900 flight test hours thus far and the total 787 flight test hours has exceeded 2,100 hours leaving 1,000 flight test hours needed to complete the test flight program.

Flightblogger: 787 goes cross country to check the gas gauge

While the test flight program continues to make progress, there are signs of production troubles on the 787 final assembly line. ZA233, the 29th 787s to be assembled was initially supposed to start final assembly on Oct. 4th. It was pushed back to late October, then early November and now I got news that it won't start assembly until around November 17th...over 6 weeks late. To add to the mystery, Matt Cawby got video of a rear and forward 787 fuselage sections being loaded back on to the 747 LCF in Everett instead of being offloaded. Now the LCF did not depart Everett so my guess is that they might be being stored on board the 747 LCF. I am hoping to hear from Boeing about any production pauses on the 787 line and what reloading of the fuselage sections on the LCF may mean.

Interesting Video of 787 parts in Everett

Matt Cawby who regularly shoots video and photos of Boeing's Everett flight line recorded an interesting piece of video yesterday at Everett which is below:


Matt Cawby Video


In the video the 747 LCF is loaded with fuselage section for the 787. What is interesting is that these are not the pre-stuffed ready to join sections that would normally arrive into Everett to be taken to final assembly but parts that are normally constructed by Alenia in Grottaglie, Italy and then flown to Boeing Charleston to be assembled with parts from Japan to form the main fuselage section that is finally delivered into Everett. Why these particular parts were flown direct to Everett and not Charleston is a mystery but I think we can reasonably speculate that because of Boeing's review of Alenia production processes and manufacturing standards, these parts might be part of the inspections that Boeing has ordered across all the 787 that have been built. Hopefully there is nothing seriously wrong with the parts but it does say that Boeing is a little nervous about one of its major suppliers.

Boeing restarts 787 part deliveries into Everett

As I had reported last week, Boeing will restart 787 final assembly on Monday, June 14th. This is reinforced with the restart of LCF flights bringing the required fuselage sections into Everett. Yesterday and LCF flew in the rear fuselage for the next 787 to be built...ZA177 (LN 23) for Japan Airlines and horizontal stabs for Air India's first 787, ZA230 (LN 25). Later this afternoon, the forward fuselage will be flown from Wichita to Everett. There should be a line move late this weekend to allow parts for the 23rd 787 to be located in the assembly tool in building 40-26.

Flight Test

ZA002 flew a 2 hour and 35 minute mission this morning (June 8th) out of Victorville. In completing this test flight, the 787 test fleet has completed over 30% of the required 3,100 test flight hours for the program. ZA005 continues its gauntlet testing ahead of a planned first flight on June 16th.

Albaugh speaks at JP Morgan Aerospace Conference

James Albaugh, Boeing Commercial Aircraft President, spoke at a JP Morgan Investors conference this morning. Here are a few snippets:

• 787 should receive the TIA (Type Inspection Authorization) by the end of this month (March).


• Boeing right now putting out 2 787s per month will be up to 2.5 airplanes per month by August, 2010 and up to 10/month by end of 2013.


• ZA003 should fly this Sunday (confirms what I had reported earlier here)


• ZA001 reached speeds of around M0.97 (in a dive) during testing.


• Expects first 787 delivery from Charleston in 1st quarter 2012


• Boeing has used up some of the 787 flight testing contingency and had about one to one and a half months of contingency left in the test flight program.


• New 747-8 coming "on line" on March 15, 17 (this means that Initial Airworthiness Testing is complete by then so that the two remaining 747-8 test airplanes will be in the air next week).

In other news, ZA003 ran its engines yesterday on the Boeing flight line and should be conducting its gauntlet testing towards the end of this week followed by first flight on March 14th. ZA002 has departed this morning for Victorville where it will continue flight testing.

A bit of surprising news is Boeing's award of 747 LCF Dreamlifter operations from Evergreen International to Atlas Air.

Unsurprisingly, Evergreen International is upset but their contract was for 35 years but is renewable every 5 years and it was due for renewal this year. Here's an article focusing on Evergreen's reaction.

Also, unsurprisingly, Flightblogger is reporting that the LCF contract was given to Atlas as part compensation for the delays to the 747-8F, 12 of which Atlas has ordered. Atlas is due to take over LCF operations from Evergreen this September. Boeing will retain ownership of the 4 LCFs.

Flightblogger: Sources: Dreamlifter Deal Part of 747-8 Compensation to Atlas

Fleetbuzzeditorial.com : Boeing's Big Choices

787 & 747 Tidbits

Well know that Boeing has two major programs in test flights here's some updates.

787

Boeing announced that the fourth Dreamlifter is now in service after the 747-400 underwent major reconstructive surgery (like it's 3 sisterships) in Taiwan. Here's Boeing's Press Release:

News Release Issued: February 16, 2010 2:51 PM EST

Final Boeing 747 Dreamlifter Enters Service
EVERETT, Wash., Feb. 16
/PRNewswire-FirstCall/ -- The fourth Boeing (NYSE:BA) Dreamlifter – the final airplane in the fleet of specially modified 747-400s – entered service today. Dreamlifters transport the large composite structures of the 787 Dreamliner from partners around the world to Everett, Wash. for final assembly. The unique airplane, which was modified by Evergreen Aviation Technologies Corp. in Taipei, Taiwan, took off from Paine Field in Everett early this morning. Bound for Wichita, Kan., the Dreamlifter is returning the equipment used to transport the forward fuselage section known as section 41. The airplane's registry is N718BA.

I heard a couple years ago that Boeing may need as many as 6 Dreamlifter to support the higher production rate. With the Charleston Assembly Line due to start production middle of next year Boeing may have to procure two more low mileage 747-400 for conversion to LCFs to meet the higher expected output.

In the meantime ZA003 underwent more ground testing as does ZA004. Both aircraft still are expected to be in the air by the end of the month with ZA005 in the air by March and ZA006 flying by the end of April.

Flight testing continues with ZA001 starting flutter tests on February 14 with this testing expected to last a few weeks. Soon after that the 787 should receive its TIA (Type Authorization Inspection) which will be the formal start of certification flights with FAA inspectors on board the test flights.

Guy Norris has a great blog post detailing the 787 flutter tests.

787 - Forward to Flutter

On the production front, Boeing has sent airplane 13 to the paint shop after it had completed final assembly activities in building 40-26. Airplane 17 moved into position 1 for the start of final assembly and parts for airplane 18, destined for ANA, has started to arrive in Everett.

747-8

Since conducting first flight of the 747-8F, Boeing has been conducting further ground tests on RC501 as well as checking out the aircraft in preparation for the next flight speaking of which should occur as early as this coming weekend. RC521 is continuing its preparations for its first flight which should occur after RC501 as completed initial airworthiness flights. In the meantime, Boeing released some very spectacular images of RC501's first flight around the Seattle area.

All photos below are Boeing Photos:

Some 747-8 news and some 787 news

Ok switching gears for a moment. Here's some 747 news. Flightblogger is reporting that the first 747-8 will start 40 hours of final gauntlet testing later this week. Final gauntlet tests the aircraft's systems and subsystems by making the airplane think that it is flying and seeing how those systems react.

First flight is probably going to occur sometime in February though I still don't have a firm date. That date, like the 787 first flight date before it, is dependent on the results of gauntlet testing and the need, if any, for any further testing.

Guy Norris reports that Boeing is working through a long list of EWAs (Engineering Work Authorizations) which is a long name for systems checks. Boeing has been working on a series of systems to make sure they're ready for final gauntlet. Guy says that given that final gauntlet hasn't started means that first flight won't occur until very late this month to middle of next month.

Matt Cawby got a couple of nice picture of the two 747-8F on the Boeing flightline. Curiously both are registered N747EX.

Lastly, in a somewhat related note, Flightblogger says in his post that the 4th LCF for the 787 program is due in Everett next month after taking it first flight (post conversion) on Friday, January 15. In a 787 related update, ZA004 will be testing the 787's evacuation slides this week and ZA001 will hopefully start further flight envelope expansion tests with further flutter and primary flight control system tests followed by high speed stability and control testing.

Randy Tinseth, in a blog posting on Friday, January 15, talks about the 787 achieving its Initial Airworthiness testing milestone and notes that the 787 fleet has accumulated 59 hours and 15 minutes of flight test time. Using flightware I've calculated 59 hours and 40 minutes of flight time which is close.

Flightblogger's Week Ahead Post

Guy Norris: 747-8 Flight Test Update

Matt Cawby: January 15 747-8 Update

Boeing Prepares 747-8 Flight Test Program

Randy's Journal: Initial Airworthiness

787 flight tests off to a promising start

Flightblogger: 787 First Flight Date's a Moving Target

Well the title sums it all up. I even heard a date of Dec. 12th though I really think that date is not realistic. One pattern is emerging: the date is going to be between Dec. 14th and Dec. 22nd and Boeing is marching towards that date.

Flightblogger reported that Boeing performed software checks as well as testing the thrust reversers. The final gauntlet testing is still schedule for next week and ZA002 is inside going through some final reassembly activities as well as getting it's fuel tanks washed out.

Also Matt Cawby reported on his blog that Boeing conducted VHF radio checks on the same frequency that was used for the taxi tests. The nose section for LN14 (Dreamliner 14) was delivered today on the LCF from Spirit Aerosystems.

Flightblogger

Matt Cawby

First 747-8F out of paint Hangar

Boeing Photo

Boeing showed off the newest version of the 747 painted in the Boeing "light" scheme. It will now proceed for fueling tests followed by APU start and then first engine start and intermediate gauntlet.

In a little bit of 787 news, the fatigue test air frame is now in the temporary tent hangar on the Everett flightline which may mean that this air frame may be next to undergo the side of body modification. A 747LCF also delivered the next horizontal stabilizer for Dreamliner 13.

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

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.

July 30 787 Update

Now that we're at the end of July I thought that it would be a good time to look at some articles that have recently come out regarding the 787 since the earnings call last week. Many people were disappointed that Boeing doesn't have any new schedule ready as of now. They said that the new schedule will be ready during the third quarter (of this year I think) so we'll see by September 30th what will happen.

Start things off, Flightblogger reported that because of the need to modify the brake control monitoring software due to overheating of some of the braking elements during a high energy (trying to stop a heavy and fast aircraft), there is a conflict between Boeing and Crane who wrote the code over who should pay for it. Crane claims that they delivered into Boeing the software they needed and that their production costs already exceeded their initial projects without and of the needed redesigns. There are a lot of revealing comments in Flightbloggers posting.

Flightblogger: Boeing and Crane

Next up, Guy Norris reports that despite the wing issues, Boeing is still doing some ground testing on the 787. Guy reported that Boeing is continuously testing upgrades to the 787 software during a Wedge Regression Test (don't ask me what that is).

Guy's July 24th 787 Update

Third, Mike Mecham, Joe Anselmo and Guy Norris talked about Boeing's lack of a schedule for the 787 and the implications (financial and otherwise). they cite skeptical analyst who believe that the schedule will move further to the right as well as the possible implications regarding costs associated with the fix and testing that has to be done.

Aviation Week's 787 Schedule Elusiveness

Batting clean up, is Dominic Gates and the Seattle Times with further analysis of the side of body issue and the seriousness of the problem (which appears to be more severe then initially revealed). In the article, Dominic Gates says that there was damaged done not just to the wing boxes (the main wing structure) but also to the center wing box which is in the fuselage. Damage occurred not at ultimate load (150%) but at a load much lower than that which explains why Boeing decided (for good reason) not to proceed with flight testing. The flight envelope would have been so limiting that it would have been useless to fly any test flights since the data collected would have been minimal. It seems from reading the article that Boeing would have to reinforce not only the wing side but the fuselage side of the side of body.

Seattle Times: 787 Wing flaw extends to inside of plane

Fifth, Boeing had moved ZA001 to the paint hanger for preliminary work before the installing the reinforcement fix. Flightblogger had said that Boeing did plan to move ZA001 into the paint hanger for the fix and that the fix may be installed as early as mid August. Aircraft ZA001 has since been moved back out to the flightline. Parts for ZA102 (third production 787) has already arrived save for the rear fuselage (as far as I know). Final assembly should be getting underway soon. My last note is that the large cargo freighters (LCF) have been making a lot of runs as of late though as I said before, it's hard to know what's, if anything, is being transported unless you have someone there photographing the loading and unloading of the aircraft.

Lastly, Boeing just completed the transfer of Vought's 787 operations today and will now be known as Boeing Charleston.

News Release Issued: July 30, 2009 2:00 PM EDT

Boeing Completes Acquisition of Vought Operations in South Carolina

SEATTLE, July 30 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) announced today the completion of the acquisition of the business and operations conducted by Vought Aircraft Industries at its South Carolina facility, where a key structure for the 787 Dreamliner is built. The acquisition agreement was announced originally on July 7.
The newly acquired facility, located in North Charleston, will be called Boeing Charleston. Boeing Charleston will be managed by the 787 program as a wholly owned subsidiary. Boeing Charleston will continue to perform fabrication, assembly and systems installation for 787 aft fuselage sections, which are made primarily of composite materials.

Seattle Times: 787 May Not Fly This Year

In an article that echoed Flightblogger's post yesterday, Dominic Gates of the Seattle Times reported that the 787 may not be ready to fly this year due to the required fix needed to the side of body join. I reported earlier that the detail design of the fix itself would take two months followed by manufacture and testing of the fix. Adding to the complication is accessibility to install the new parts. The design of the parts can also complicate the ramp up to full production of the 787 because of the time needed to retrofit the parts in airplanes already assembled as well as those still back in the supply chain. Boeing wants to avoid retrofitting too many assembled aircraft.

However, looking at the LCF flights that Boeing and Evergreen have been flying, there seems to be quite a bit of activity. Granted some of these flight might be training flights and/or repositioning of transport fixtures for the various parts, the activity could also mean an increase in activity especially with regards to build up of the main fuselage section which is still an issue in terms of the build up time.

Seattle Times: 787 May Not Fly This Year

Two Dreamliners and a Dreamlifter

Matt Cawby got this great shot of two 787s and the 747LCF together (sort of). Kind of a cool picture.

Two Dreamliners and a Dreamlifter

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.

Flightblogger: ZA001 intermediate gauntlet to start today

UPDATE: Flightblogger is reporting that gauntlet testing along with the pre-gauntlet engine tests won't start until tomorrow. Today was "Shop Gauntlet Work" that took place.

Flightblogger is reporting that intermediate gauntlet testing on ZA001 may start as early as mid day today.

Boeing was to have some engine runs today followed by pre-gauntlet test meetings following those engine runs.

If things look good then Boeing should start the intermediate gauntlet tests today starting with a simulated first flight profile test with simulated failures of the aircraft systems. Boeing had already run through the intermediate gauntlet tests on the integrated test vehicle (ITV).

Lastly, Jon reports that ZA002 ran through its gear swing tests and ZA004 and ZA005 have their engines. That's Trent 1000s for ZA004 and GEnx for ZA005.

Also it appears that the LCF is not delivering the main fuselage section for ZA100 today.

Jon's May 28th Update

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.

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.