Boeing to start 787-9 final assembly on May 30

Source revealed that Boeing will load ZB001 (LN 126, N789EX) on May 30th. This should lead to the rollout of the aircraft approximately 2 months later in late August. First flight is anticipated later this fall though timing is still uncertain.

Boeing has taken delivery of ZB001's horizontal and vertical tail plane as well as the wings.  In the coming two weeks we should see the delivery of the fuselage sections into Everett.

Boeing is shifting production of 787-8s to the main 40-26 and 88-03 assembly lines in Everett in case issues with the assembly of the first 787-9 encounters problems in 40-24. Already Charleston is taking on more 787-8 but the bulk of the 787-8 production will go to the main final assembly in Everett.

The other two 787-9 test airplanes will follow ZB001 in the 40-24 surge line.

Meanwhile Boeing has resumed deliveries of the 787-8. ZA513 (LN83, JA818A) was delivered to ANA marking the airlines 18th 787 and Boeing's 51st 787 delivered.

LOT Polish Airlines was to have taken its 3rd 787 (ZA272, LN 86, SP-LRC) today but that is being delayed due to some minor issues with the aircraft. Delivery is now expected to take place around Thursday.

 

787 production testing accelerating

In the last 8 days Boeing has sent 6 787s into the air for each aircraft's first flight since the grounding ended.  This included two 787s that were flown on their B-1 flights today, April 30th.  Boeing had indicated that they would aggressively conduct production testing in order to get caught up on deliveries.  Though Boeing hasn't delivered a Dreamliner since the grounding ended, they have said that deliveries would re-start in early May.  It may re-start by the end of this week though I do expect that ZA512 (LN 83, JA818A) should be delivered sometime next week after customer test flights are conducted by ANA pilots.

I expect that in the next 8 weeks, Boeing should be able to deliver 787s to Air India, JAL, ANA, Qatar Airways, ILFC (for Norwegian), LOT Polish Airlines, Hainan, Thomson Airways, and China Southern.  Thus far, 787s for Hainan, Air India, ANA, Thomson, LOT Polish, and JAL have entered production test flights with the revised lithium ion battery set up and there is a pattern.

Boeing is conducting test flights roughly in order that each aircraft emerged from final assembly.  There have been exceptions most notably a Hainan airframe which does not have any engines and a couple for LOT which are expected to be delivered later in the year.  If the current pattern holds then I expect that from Everett the following will be making their first flights in this order:

ZA383 - China Southern
ZA318 - TUI
ZA319 - TUI
ZA513 - ANA
ZA185 - JAL
ZA465 - Qatar

From Charleston these aircraft will be making their first flights in this order:

ZA434 - Hainan
ZA243 - Air India
ZA384 - China Southern
ZA385 - China Southern

I estimate that Boeing can deliver between 12 to 14 787s by the end of the second quarter including a few to Chinese carriers who are expecting that the 787 will be finally given its airworthiness certificate by Chinese authorities next month.

Prior to the grounding it took Boeing about 6 weeks after rolling out a 787 to the flightline to conduct all the necessary company and customer tests, finalize paperwork and make final delivery.  I see no reason why that would change now, though some aircraft that have already had quite a few test flights done prior to the grounding won't take that long since much of the flight testing is already completed.

Flight testing will continue to pick up pretty aggressively over the next few weeks as Boeing needs to work down the inventory of 37 787s that have built up over the last few weeks.

 

787 production update

As we approach the Holiday week, Boeing will be going into a slow down mode as is the custom around this time of the year.  There have been moves of late which I'll highlight here.

Boeing has moved out ZA274 (LN 88, SP-LRE) for LOT and ZA184 (LN 89, JA830J) for Japan Airlines.  They moved ZA513 (LN97, JA819A) for ANA into the body-wing join in 40-24 to start final assembly.  This is the last aircraft that will start final assembly in 2012. I expect it to be delivered sometime around middle to late February 2013.

Boeing also moved ZA232 (LN 28, VT-ANC) to the EMC to begin the change incorporation process for this airframe prior to delivery to Air India sometime next year.

I have also updated the tables to reflect the firing order for airplanes 116 to 130. The highlight of this list is ZB001 (LN126) which is the first 787-9 to go into final assembly.

There are a couple of things that caught my attention when I saw the list.  Boeing is assembling this aircraft on the 40-24 surge line and not on the main assembly line in 40-26.  Second, Boeing has diverted the final assembly of the 787-8s from 40-24 and is concentrating the production of customer aircraft in 40-26 and 88-03 in Charleston.  This is obviously in case they run into issues during final assembly of the first 787-9 that there aren't any bottlenecks in 787-8 production.  They are leaving themselves enough margin, it seems, to address issues with assembling the 787-9.  There will be a 3 airframe margin in front of the ZB001 and at least a 4 frame margin behind the aircraft as it makes it way through the final assembly stations in 40-24.

I don't have any information on follow on 787-9 frames just as yet but Boeing is believed to be planning for a 3 aircraft test fleet for the 787-9 with the test program lasting about 6 months.  I roughly estimate that ZB001 should enter the final assembly building around June 13, 2013.  Boeing has said the aircraft will start final assembly during the summer.  Since this is a brand new variant, I am assuming at least 6 weeks for final assembly and another 6 weeks for ground testing before first flight.  This would mean that this airplane can be flying around the middle of September, 2013.

On the firing order nothing stands out though we do get to see the first 787 for JetStar going through final assembly as well as the first 2 787s for Royal Brunei Airlines.  The Royal Brunei Order is listed as unidentified on Boeing's Order and Delivery website but they did order  787-8s with Trent-100 engines.  The airlines says that they are expecting to take delivery of the 1st 787 in early September 2013. This list as it stands now would cover deliveries through early September, 2013.

787 testing picking up as deliveries continue

787 flight activity picked up this week as the weather cleared long enough for Boeing to send up another 787 on its 1st flight.  Yesterday There were 4 787 flights including the B-1 flight for ZA285 (LN 45, N27901) for United Airlines.  There was supposed to be another test flight of ZA238 (LN 54, VT-ANJ but it didn't occur.

As Boeing aggressively ramps up flight tests this month deliveries are also starting to take shape. This evening, Boeing delivered United's 4th 787 (ZA289, LN 55, N45905).  According to a press report by Bloomberg, Qatar is expecting to take delivery of two 787s on Dec.19th. I also expect Boeing to further deliveries of 787s to ANA (2), United (1)and JAL (1).  Wild card deliveries can be made to Air India (2) and possibly China Southern (that airplane still has to make its 2nd test flight).

Now all this continues despite the recent spat of glitches that the 787 has experienced.  The most notable one is the issue with the starter generator supplied by Hamilton Sundstrand.  A second 787, ZA460 (LN 57, A7-BCA) experienced the fault and landed while being delivered to Doha from Victorville.  The generator is being swapped out and the aircraft should enter service soon but the issue is troubling.  Akbar (U-Turn Al) Al-Baker again vociferously complained about the teething problems of the 787 to the media (after the first revenue flight of Qatar's 787 to London) but Qatar is still planning to take delivery of 2 787 next week.  Still Boeing along with Hamilton Sundstrand and the FAA are looking into the issues.  Jon Ostrower of the Wall Street Journal reported that 2 other 787s are affected...one other delivered 787 that belongs to United and an undelivered 787 for Qatar (one of the two that are to be delivered next week). The FAA said the issue doesn't appear to be safety of flight issue and aside for Air India reporting unspecified "electrical problems" no other 787 customers have come forth with electrical probles as of late.  Dominic Gates of the Seattle Times also has an article on the 787 electrical issue.

On the production front, expect things to slow down as Boeing enters its traditional Holiday break.  One aircraft (ZA513, LN 97, JA819A) for ANA will be loaded into the final assembly line and that will be the last until after New Year.

As of today, Boeing has delviered a total of 40 787 to 8 customers worldwide.  They've delivered 37 in 2012 and have to potential to deliver anywhere from 6 to 8 more airplanes this month.

Boeing 787 firing order updated

I've been able to update the firing order for the 787. Not too much of a surprise but two new customers will be getting aircraft from this batch including the first lessor, ILFC.  Here's the round up but please keep in mind that this firing order can change.

Charleston
The Charleston plant will be building 3 Dreamliners including one  for Air India (ZA243) and 2 for China Southern (ZA384 and ZA385).  These are existing customers.

Everett
With the surge line now operational we'll be seeing an increase in output from Everett.  First delivery customers are ILFC (being leased to Aeromexico) (ZA560) and Thomson Airways (ZA317) and (ZA318).  Current customers include China Southern (ZA383), ANA (ZA513), Japan Airlines (ZA185), and Qatar Airways (ZA465).

In the meantime two more 787s have gone into the paint Hangar including the first 787 for LOT Polish Airlines, ZA270 (LN 61, SP-LRA) and the 4th 787 for Ethiopian ZA261 (LN 44, ET-AOP).