Another correction, JAL took delivery of the 100th Dreamliner (seriously this time)

There has been plenty of confusion as to who received the 100th Dreamliner but thanks to Greg, an eagle eyed reader of this blog we might be able to finally declare who the winner is:

Japan Airlines received the 100th 787.  It was ZA175 (LN 20, JA821J)

this aircraft was seen by Matt Cawby at the Everett Delivery Center on Nov. 5th and a Flightwaware alert popped up showing that this aircraft was to leave that evening for Tokyo.  The aircraft never left and was ultimately towed back to the flightline at Everett.

Since then Hainan Airlines took delivery of a 787, ZA434 (LN 85, B-2730) at Charleston and flew it to China so that left many assuming that this aircraft was number 100.

Then Greg found a posting on Boeing's New Airplane Flight tracker web site.  Boeing has delivered 101 787 as of November 8, 2013.  This can only mean that ZA175 was delivered as not other 787 except for ZA434 has been seen at the Everett Delivery Center or the Charleston Delivery Center.  Since ZA175 was at the EDC on Sept. 5 and ZA434 showed up at the CDC on Nov. 8th it should follow that ZA175 was delivered before ZA434.

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

 

Second 787-9 takes flight, Boeing delivers 100th 787 (for real this time)

 

Boeing Photos

Ok so I have to backtrack a little bit.  Last week ZA175 (LN 20, JA821J)for Japan Airlines appeared at the Everett Delivery Center and later in the day Flightaware.com showed a delivery flight planned for that aircraft to Tokyo.  This was, I assumed, the 100^th delivery of a 787 to a customer and I reported it as such. However, the flight plan timed out and a couple of days later the aircraft was towed back to a flightline stall.  Now the aircraft may have been contractually delivered but I am not sure.  Right now it seems that ZA434 for Hainan Airlines (LN 85, B-2730) looks to be the 100^th delivered 787.

Given the high level of interest in the 787 I would have expected that Boeing would have made some comment about the delivery but as of yet there hasn’t been any communication about it even after I’ve made an inquiry about it.  Boeing is being very quiet about this which seems to suggest that there might be some sort of behind the scenes issue with who is the actual recipient of 787 #100 or Boeing is waiting to make a very big splash about it at some later date.

As far as production goes, Boeing is still making very good progress in ramping up the rate in the factory.  November has been slow in terms of production testing after last month’s flurry of flight test activity.  There are still 4 aircraft including the aforementioned ZA175 waiting to be delivered.  Boeing has delivered 2 aircraft through the first 10 days of this month though I still see Boeing able to deliver at least 6 more aircraft this month.  They will have to start moving planes out of the flightline and into customer hands if they’re to increase the rate and avoid have a glut of 787s crowding the Everett and Charleston ramps.  This week will probably be critical in terms of determining the progress in delivering these Dreamliners.  Boeing will need to get a few (about 4) more aircraft up doing their B-1 as well as have the 6 airplanes that have already started production testing flying their customer flights.

Last week ZB002 (LN 133, N789FT), the second 78-9 test aircraft, flew for the first time in a 4 hour and 18 minute test flight.  The following day, ZB001 (LN 126, N789EX) resumed test flights after spending a week at Everett.  No reason was given for the 1 week layover but I suspect it was to fine tune the aircraft and possibly change out some flight test equipment.  ZB021 (LN 139, N789ZB) had its GEnx engines run for the first time and I suspect will join the test flight program sometime around mid-December.  In the meantime, Boeing is continuing production work on the first 787-9.  ZB197 (LN 146) is destined for ANA and will be used for some of the final testing activities that the FAA mandated to be done on a production standard aircraft. I expect that this aircraft should roll out by late November but I don’t expect that it will be needed for any test flights until February at the earliest.  I still expect that the first 787-9 should deliver to Air New Zealand around April, 2014.

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

 

Boeing delivers 100th 787 to Japan Airlines

While I have no official confirmation nor any word from Boeing, it appears that the 100th 787 to be delivered went to Japan Airlines this afternoon.  There was a flightplan just filed on Flightaware.com.  The aircraft is ZA175 (LN 20, JA821J) which is one of the early buiild 787s that had to go throughthe long process of change incorporation.  So far I have not heard of any aircraft being delivered from Charleston as of yet.  ZA175 is currently at the Everett Delivery Center.

Boeing has delivered 51 787s in 2013, and 100 aircraft since the start of deliveries in September 2011.


Full 787 List

Current 787 Production List

Delivered 787 List

787 Monthly Delivery Tracking

787 Customer Delivery

787-9 Flight Test Hours

 

Boeing equals 2012 787 delivery total.

Mid way through October Boeing has delivered 46 787s which is the same number that they delivered in all of 2012.  They've made great progress in bouncing back from the battery issues that grounded the world wide fleet and halted deliveries.  Through Oct. 6th, Boeing has delivered 95 787s and looks to deliver the 100th 787 later this month. Which one will get that honor is up in the air but it should still happen this month as there are several 787s that are in the middle or have completed their production testing.

Given we're at month end I think there is a little bit more clarity to the delivery schedule for the rest of this month.  So far in October Boeing has delivered 6 787 including 4 from Charleston.  Boeing, I believe, can deliver another 6 to 8 aircraft as follows:

ZA175 (LN 20, JA821J) to Japan Airlines
ZA235 (LN 32, VT-ANG) to Air India
ZA381 (LN 36, B-2726) to China Southern Airlines
ZA434 (LN 85, B-2730) to Hainan Airlines
ZA386 (LN 104, B-2737) to China Southern Airlines
ZA562 (LN 122, N964AM) to ILFC/Aeromexico*
ZA563 (LN 127, N965AM) to ILFC/Aeromexico*
ZA446 (LN 130, V8-DLB) to Royal Brunei Airlines

* Dependent on US Govt. shutdown

While it looks good that the US government may reopen as early as tomorrow this could help with the deliveries to US-based buyers like ILFC.  ZA562's deliver, it seems, has been delayed as the FAA's registration office in Wichita, KS has remained closed because of the budget debacle.

While Boeing has been pretty aggressive with conducting production flights for the first half of the month, things seems to have quieted down in the last couple of days indicating that Boeing may be making taking some corrective action on the airplanes that they have flown before conducting customer acceptance flights or are preparing for those customer flights which would get underway shortly.  Additionally, Boeing is preparing to fly the second 787-9 (ZB002, LN 133, N789FT) within the next week though no date has been given. So far the 787-9 test program has accumulated just under 94 flight test hours.

Looking ahead, it seems that Boeing might be gearing up to increase 787 output per their plan.  10/month by the end of the year is still their goal and they seem to be on the verge of achieving it. Sources have told me that LN 158 will be the first airframe that will be produced at 10/month.  This aircraft is slated to be built in Charleston.  Boeing appears to be loading a 787 frame into position 1 every 14 to 16 days.  Extrapolated this would mean that ZA244 (LN 158, VT-ANP) should load (and Boeing would start producing 10/month) around December 8th.  Boeing is quickening the production rate which did slow down due to the 787-9 flight test aircraft assembly.

Lastly, with the government shutdown seemingly coming to an end, I'd like to leave you all with this:

So... the good news is that you're getting the government back, and the bad news is that you're getting THAT government back.
— SarcasticRover (@SarcasticRover) October 16, 2013

Full 787 List

Current 787 Production List

Delivered 787 List

787 Monthly Delivery Tracking

787 Customer Delivery

787-9 Flight Test Hours

 

Weather likely to slow down 787 deliveries over next few days

The Everett weather may be looking to put a hold on deliveries for the next few days and may ground aircraft  all together.  The Seattle area is expecting rain....a lot of it as Mt Ranier is forecasted to have 10 FEET of snow but the lower elevations, while not getting that much, will probably be clobbered as well with large amounts of rain.  Boeing is still stuck at 35 deliveries in total to 8 customers.  There has been some movements of assembled aircraft with ZA504 (LN 15) moving to the Runaway storage area and ZA150 (LN 17) moving to the EMC.  In a surprise move, ZA381 (LN 36, B-2726) was moved to the EMC, ostensibly for change incorporation.  This MAY indicate some movement to deliver 787s to the Chinese (China Southern and Hainan) but it's too early to tell.  This aircraft could easily go back to the temporary parking/storage that it had previously occupied. ZA175 (LN 20) finally made it inside the EMC to continue change incorporation and finally ZA287 (LN 52, N26903) was moved to the paint hangar and should be out soon. Interestingly ZA285 (LN 45, N29601) is still out on the flightline even though it was pulled out of the EMC earlier.

With the Thanksgiving holidays coming up along with the rainy weather in the Pacific Northwest, don't expect too much happening out of Everett this week.  There is supposed to be a line move early next week.  Lastly, there is a rumor that Air India will be able to pay for another 787 this week and fly it away from Charleston but so far nothing has happened.

Another 787 pushed out, airplane 66 out the door

Boeing has pushed out ZA135 (LN 66) from build 40-26.  This is supposed to be the first airplane that goes from assembly line to flightline.  Currently it is parked on the 40-51 (building) apron west.  I don't know if it has its engines attached or not but hopefully a spotter would be able to get photos of it to determine if it engineless and buttoned up like other 787s that have to go through the change incorporation process or if the windows and doors are uncovered and the airplane has its engines hanging off the wings.  If, as expected, this airplane has its engines then it should be ready to go to paint/aqueous wash followed by ground and flight testing prior to delivery to ANA.
We have to wait and see but this information is current as of today. 

Additionally there are 3 787s in 40-24 undergoing change incorporation.  These airplanes are ZA175 (LN 20) for JAL, ZA261 (LN 44) for Ethiopian and ZA287 (LN 52) for United.

No word on upcoming deliveries in June as of yet.

787 Production Movement

Boeing is preparing to restart final assembly on the 787s by June 14th but until then there will be movement of currently assembled airframes around Paine Field.

To start ZA006 the last test flight aircraft and the second to be equipped with the GEnx-1B engines will be pulled out of building 40-24 tomorrow night and taken out to the Boeing flightline to be prepared for its first flight expected around July 13th.

ZA100 (LN 7) will be moved out of building 40-26 on Sunday June 13th and will be placed inside 40-24.

After the line move ZA101 will occupy position 4, ZA102 will occupy position 3 and ZA115 (LN 22) will be moved to position 2 all inside building 40-26. This will make room at position 1 for ZA177 (LN 23) to start final assembly on June 14th.

ZA005 will conduct its first flight on June 16th and will create on empty spot on the flightline (their going to need it)

After a couple of weeks, there will be another line move with ZA101 being moved to 40-24 on June 27th. The aircraft that are in 40-26 will be moved one position to make room for ZA116 (LN 24) to start final assembly on June 28th.

After about another two weeks there will be another move with ZA102 being moved out directly to the flightline on July 12th. On July 13th ZA230 (LN 25) will start final assembly.

Interestingly when Boeing put the temporary halt into effect ZA175 and ZA176 were moved into the ATS Hangar and they will remain there. The aircraft are not finished and I think Boeing will probably finish them at ATS.

Lastly, all the completed 787s and 747-8 are going out to the flightline without engines and interiors. This is so Boeing will not have to pay the suppliers for these items until they're needed to be installed which is closer to their first flight dates.

787 and 747-8 Update - April 12, 2010

This past weekend it was expected that Boeing was to fly all four 787 (ZA001, ZA002, ZA003, and ZA004). Both Guy Norris and Flightblogger reported this. This would have marked the first time that all four test airplanes would have flown and hopefully it will allow Boeing to start accumulating more test flight hours. Unfortunately, only ZA001 flew during this past weekend.

According to Guy Norris, ZA002 flight that was expected to take place on Saturday is now scheduled to fly on Monday, April 12th as Boeing wanted to conduct more ground tests on the aircraft which has new flight control software installed. It is flight testing of this new version of the software that will allow the FAA to issue the TIA (Type Inspection Authorization) and allow certification flight testing to proceed. The TIA was expected at the end of March and that was delayed from mid February. If the TIA is issued by the middle of April then the 787 program would have lost an additional 1/2 month of schedule margin.

ZA003 second flight was to have taken place yesterday, April 11th but it did not fly. The reason is unknown but this test flights are to signal the start of environmental control systems testing on board that aircraft as well as testing other systems on the aircraft including the RAM air systems.

ZA004 is going into a planned layup and will not fly until the end of April at the earliest. ZA001 is finishing up the last of stability and control flight tests and will now focus on low speed performance flight testing.

According to my accounting, The Boeing test fleet has accumulated almost 460 test flight hours as of April 11th. On April 9th, ZA004 flew the longest 787 test flight to date which is 6 hours and 40 minutes.

Flightblogger also reported on a potential problem with stringers in the rear of the 747-8 upper lobe (hump). The flange of the stringers may be to thin to handle the loads and thus would need to be replaced. Boeing and Vought (contractor) are studying the issue which may need to be resolved by replacing the stringers in question, a costly and time consuming process. Flightblogger says that the 747-8 in the test flight program would continue test flight under restrictions on their g-loads but they would continue. He says that the 747-8 is now entering flutter testing. So far I've show that the 747-8 program has accumulated just under 108 flight hours through April 11th. Flightblogger says that Boeing is thinking about using on of the production aircraft to augment the 747-8 test fleet. This aircraft would not be instrumented for the test flight program like the other three aircraft are but would perform engineering flight tests. The aircraft under consideration is RC503 which is the second production aircraft and is currently in the paint hangar at Everett.

Read Guy's and Jon's articles here:

Flightblogger: 747-8F begins flutter testing as stringers get inspected (and other 787 items)

Guy Norris: Big Weekend for 787

Guy Norris: 787 Update

Now speaking of structural strength, Daniel Tsang of Airways Aviation News put out an interesting article on the side of body fix on the 787. As some of you may know, Boeing had to fix the side of body area due to that area being too weak to handle flight loads. The fix has been installed on 9 air frames and needs to be installed on another 8. All 787s going forward would have the side of body fix installed at the sub contractor prior to delivery to Everett though there would be some installation work to be done on the final assembly line prior to the wing-body join. It is expected that starting with LN 49, the parts that strengthen the side of body would not be needed as Boeing and it sub contractors would have redesigned those areas of the aircraft (the wing box and the center wing box) that would provide the additional strength needed and the installation of the parts would not be necessary. Daniel Tsang is reporting that the use of the parts that provide the reinforcement to the side of body would be a permanent solution though Boeing is looking to simply the production and installation of the parts by tweaking the design. You can read Daniel's article:

Daniel Tsang: Boeing looking at ways to simplify side-of-body modification

Production
Boeing is continuing to make its production milestones. ZA175 (LN 20) started final assembly on March 31st. This aircraft is a major milestone as it introduce a major blockpoint change which incorporates weight saving measures into the 787. ZA531 (LN 16) which is the second 787 for LAN came out of the paint shop painted all white (not in LAN color scheme as had been expected). Today there will be a line move as ZA176 (LN 21) will start final assembly. ZA150 (LN 17), the first aircraft for Royal Air Maroc, will be moved into the paint hangar though I don't know if it'll be painted in RAM colors. There will be another line move on April 26th when ZA115 (LN 22) will start final assembly. At that pace Boeing will be assembling 787s at a 2.5 per month clip which is what they had been expecting. I expect that Boeing will start final assembly on ZA177 (LN 23) and ZA116 (LN 24) in May.

787 review and look ahead

Now that the first quarter of 2010 has come to an end, it seems like a good time for a brief review and a look ahead.

Thus far the 787 flight test fleet has accumulated over 406 test flight hours (through March 31st) spread over 134 flight. ZA001 has conducted most of the test flight as expected with ZA002 conducting the second most flights.

There is some concern amongst many followers of this program (including articles in the Wall Street Journal) that the 787 hasn't been flown enough to achieve the needed flight test hours for certification. Boeing has said that the test flight program will entail 3,100 flight hours spread across the 6 test airplanes. In order for Boeing to have the necessary hours by mid November which is 32 weeks from now (I picked mid-November as it will allow Boeing enough time to get the production 787 ready for customer delivery by Dec. 31, 2010...another 6 weeks) they would need to fly the test fleet at a clip of 82 hours per week starting now.

James Albaugh has stated that the 787 test fleet would be flying around 90 hours per week starting around the middle of this year. However, if Boeing is to meet it's 787 delivery target that it has set for itself, then it would need to start flying longer 787 sorties starting now. Currently, Boeing is averaging a little over 3 hours per flight through the 134 flights that have been conducted thus far. Boeing does plan on flying longer flights but that probably won't occur until the FAA has issued the Type Inspection Authorization that is needed to formally kick off the certification process. That was supposed to have happened by today as of the time I'm writing this post it has not occurred.

Flight Test Look Ahead
In the meanwhile, ZA001 continues to fly test flights. ZA002 is in the midst of upgrading it flight software to the Wedge 5.5 version that ZA004 had recently tested on the ground and in the air. This is the service-ready version of the 787 flight software. It is anticipated that ZA002 should be back in the air by the end of next week (around April 9th). Both ZA003 and ZA004 should both be flying again by Saturday, April 3rd. ZA005 is on the Boeing flightline, preparing for it's first flight and should be flying around May 8th. This will be the first flight of the GEnx-1B on the 787. The last flight test aircraft (also equipped with the GEnx-1B), ZA006, should be in the air by June 4th and is currently in building 40-24.

Production
787 production continues apace with an important milestone taking place yesterday. LN 20 (ZA175), a 787 for Japan Airlines, started final assembly. This is the first weight optimized 787 to enter into final assembly and is introducing a major block point change with weight savings incorporated into the aircraft.

Boeing is slowly ramping up 787 production and the next aircraft LN 21 (ZA176) will enter final assembly around April 12th thus ZA 175 would be in position 1 for about 2 weeks before pulsing to the next assembly position. The dramatic reduction of traveled work (two words that hasn't been mentioned in some time) certainly has helped as well as the learning curve when it comes to assembling the 787s. Now the concern is managing the change incorporation process of the existing production 787s though Boeing does have a plan for that.

787 News Round Up

The 787 program continues apace with the pending TIA for the 787. Production continues with a new milestone set to take place on Monday, March 29th. That day the parts for LN 20, which is the first weight optimized 787, will be loaded into the assembly tool at position 1 in building 40-26.

The aircraft, ZA175, is destined for Japan Airlines with GEnx engines. The line will move on March 28 with LN 16 coming out and going to the paint hangar. Also on that day Boeing will hopefully be conducting the extremely important ultimate load test on ZY 997. Currently, Boeing is conducting tests on the static air frame in a build up to the ultimate load tests this Sunday. Mike Mecham of Aviation Week has a great blog post describing the ultimate load test.

Mike Mecham : The final wing bend (hopefully)

In other news, LAN airlines confirmed news that was already known...that they will take some of the early 787s. In total they're moving up the delivery of 10 787s with LN 10 and LN 16 due to be delivered in about a year from now during the 2nd quarter of 2011. Here's LAN's press release:

LAN Will Be One of the First Airlines in the World to Receive the Boeing
787 Dreamliner

SANTIAGO, Chile, March 25 /PRNewswire-FirstCall/ -- LAN Airlines S.A. ("LAN" or "the Company") (NYSE: LFL; IPSA: LAN), one of the leading airlines in Latin America, and its subsidiaries today announced that the Company signed an agreement with Boeing to adjust the delivery of ten Boeing 787-8 Dreamliners to be incorporated into the Company's long haul fleet. This new delivery schedule anticipates by three years the arrival of this aircraft, previously scheduled for 2014 and now expected starting in the first semester of 2011.

In this way, LAN becomes the first airline in the western hemisphere to receive the Dreamliner, which is expected to revolutionize the airline industry, incorporating the most advanced technology. These ten aircraft are part of the original order for 26 Boeing 787s placed by LAN in 2007 and previously scheduled for delivery between 2014 and 2019. In addition, LAN has outstanding orders for six leased Dreamliners.

The Boeing 787-8 undertook its first flight in December 2009 and is expected to begin commercial operations in 2010. It has the capacity to seat approximately 250 passengers, providing a unique in-flight experience due to innovative technological advances featured inside the aircraft cabin. In addition, Dreamliners are fuel efficient and ecologically friendly, providing a significant reduction in emissions.

The Dreamliners will assist in the renewal and growth of the Company's long-haul fleet, allowing LAN Airlines and its subsidiaries to serve international destinations, improving connectivity between Latin America, Europe and the United States.

Mr. Enrique Cueto, LAN's Chief Executive Officer, stated, "The incorporation of the Boeing 787 ensures the Company's sustainable growth while preserving the environment and incorporating state-of-the-art technology to deliver the best travel experience for LAN's passengers. LAN looks forward to incorporating this new generation of aircraft in the first half of 2011."

"Partnering with LAN Airlines, one of the world's great air carriers, is an exciting way to introduce the 787 to the flying public. We look forward to seeing the Dreamliner fly with LAN's livery. The 787 Dreamliner represents one of those rare generational advancements in powered flight that will provide superior operating economics, compelling environmental performance and unique passenger comforts. LAN and its passengers will be among the early beneficiaries of these enhancements," said Marlin Dailey, Vice President Sales Boeing Commercial Airplanes.

Flightblogger says that LAN will be joining the likes of ANA, Air India, Continental, JAL, Qatar Airways, Ethiopian, China Southern and Royal Air Maroc as operators of the 787 by 2011. Read Jon's post:

LAN confirms early 787 arrival