Boeing flies third and final 787-9 test aircraft as they move to quicken the pace of production test flights.

BOE 789 (ZB021) taking off from Paine Airport with T-33 chase plane in tow

 

Boeing 3rd and final 787-9 flight test aircraft powered by GE's GEnx-1B engines took off on its first flight this afternoon after a few hours delay.  Boeing does plan on using 2 production standard 787-9 for testing and other certification activities including functionality and reliability testing.  The first aircraft, ZB197 (LN 147) is still in final assembly but should emerge by the end of this month.  The other aircraft maybe ZB003 (LN 169, ZK-NZE) which would be the first 787-9 to deliver to launch customer Air New Zealand.

 

Boeing Photo

Here's Boeing's Press Release on ZB021's first flight: 

Boeing Flies Third 787-9 Dreamliner

- First GEnx-powered 787-9 flight

- Final dedicated flight-test airplane flies some two months from inaugural 787-9 flight

EVERETT, Wash., Nov. 19, 2013 /PRNewswire/ -- Today Boeing (NYSE: BA) flew the third 787-9 Dreamliner, the first to be powered by General Electric GEnx engines. The third of three 787-9s dedicated to the test effort, ZB021 joined the fleet some two months from the inaugural flight of the first 787-9.
ZB021 took off from Paine Field in Everett, Wash., at 12:15 p.m. local time and landed 2 hours and 44 minutes later at Seattle's Boeing Field. Boeing will use ZB021 to test engine performance as well as airplane handling characteristics such as low-speed performance and braking.
The 787-9 test program continues to make great progress. The fleet flies regularly, with the second airplane now in Florida for climatic testing, and has accumulated more than 180 flight hours and more than 60 flights. In addition to the three dedicated airplanes, Boeing also will conduct some testing on two production airplanes, the first of which is in final assembly in Everett. 787-10 development also is on plan.
Boeing is on track to deliver the 787-9 to launch customer Air New Zealand in mid-2014. 26 customers have ordered 396 787-9s, accounting for approximately 40 percent of all 787 orders.

In the meantime, Boeing, it seems in aggressively picking up the production testing pace now that they have increased 787 production to 10/month.  Starting now they will have to deliver 787s at a quicker pace.  Already we've seen Boeing fly 787s on their B-1 flights less than one month after they have been rolled out of the factory.  I believe we'll see that time span get shorter. Of the 16 airplanes that have completed assembly and that are out on the flightline, 5 have yet to fly and 2 of those are in the paint hangar in Everett.  I believe Boeing can deliver 4 to 6 more 787s by the end of this month.

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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.

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Boeing delivers 9 787s in October, up to 98 total deliveries

Boeing had delivered 9 787s in the month of October and all things considered that was a very good month.  The production test flights in Everett was slowed down by a thick fog that hung around Everett for days and reduced visibility to much less than half a mile.  Certainly not good conditions to fly.  The delays caused by the weather had probably pushed back a few delivery dates to early November for a few Everett built 787s but also a factor was customer readiness to take these airplanes.

Of the notable airlines whose 787s are ready to be delivered to them are China Southern (2 aircraft), Hainan, and Air India. I do think that these aircraft along with one each for JAL and united will be delivered during the first week of November.  There seems to have been a knock on effect of airplanes delivering a little bit later than planned. A number of 78s that were expected to be delivered by late September were delivered in early October.  I expect there to be a similar occurrence this month with the 6 aircraft that have yet to be delivered.

Now that we are closing in on the end of the year, question turns to how many 787 will Boeing eventually deliver to its customers.  As of the end of October Boeing has delivered 49 787s.  This is 3 more than the number they delivered in 2012 and their target still remains above 60.  They can reach that target by the end of November.

Here's how I think November and December will shake out in terms of 787 deliveries:

Air India - 2
ANA - 1
China Southern - 3
Hainan - 3
ILFC/Sky Blue Holdings - 1
ILFC/UAE Presidential Flight - 1
Japan Airlines - 2
Norwegian - 1
QANTAS/Jetstar - 2
Qatar Airways - 1
TUI Travel - 1
United Airlines - 1

This is a total of 19 aircraft that Boeing certainly can deliver within the next two months.  This would bring the total 787s deliveries in 2013 to 68 and 117 overall.  Boeing needs to start clearing out 787s both at Everett and North Charleston as the company prepares to increase the 787 production rate to 10/month in December.

At the same time Boeing also plans on getting the two remaining 787-9s into the flight test program.  Boeing just rolled out the 3rd and final dedicated test flight aircraft, ZB021 (LN 139, N789ZB). I expect that this aircraft should fly by late November - early December.  We're still waiting for ZB002 (LN 133, N789FT) to fly and I suspect that this will occur sometime within the next one week.  ZB001 flew back to Everett a few days ago.  The reason is unknown but I am guessing that it can be so Boeing can change out some flight test equipment before resuming flight tests.  To date, ZB001 (LN 126, N789EX) has accumulated over 150 flight test hours (I'm using Flightaware as my source).  However, by the end of the year all three 787-9 flight test airframes should be deep into the flight test program and recording an increasing number of hours. I expect the first delivery of the 787-9 to Air New Zealand by about April of next year.

Finally, I'd like to leave you all with an idea you all might want to try in your spare time:

To do list: go to a bank wearing a ski mask. Complete a normal transaction. Leave as if nothing happened.
— Ted (@OfficialTedSays) November 2, 2013

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Boeing starting to push 787 output rate higher; Fog lifts (for now) in Everett

According to the firing order for Everett, Boeing is planning to gradually increase the production rate at Everett using both the permanent and surge line.  Boeing had placed 4 current in production 787s on the surge line in 40-24 leaving open the first two positions on the main final assembly line in 40-26 open.  The last two positions are occupied with ZB021 (LN 139, N789ZB) and ZA560 (LN 141).  This allows Boeing to increase the production rate without impacting any upstream or downstream airframes.  Starting next week, Boeing will be loading a 787 every 4 to 6 days.  In 40-26 the period between loadings looks to be about 10 days while in 40-24 the period between loadings appears to be about 10 to 11 days.  This means that a 787 should be going through each line in about 40 days or less.  When Boeing loads a 787 every 3.5 days in Everett (between both main and surge lines) they will be hitting a rate of about 8.5 787s per month which coupled with the 1.5/month from Charleston allows the 787 program to attain the 10/month.  I think they'll still achieve this rate sometime in early to mid December.

The air around Everett is getting clearer, literally.  Everett has been plagued by a constant bank of fog over the past few days which has severally limited test flight operations of the 787.  It hasn't had an effect on flights from Boeing Field as ZB001 continues to fly from that airport.

Today alone Boeing sent up 5 production 787s from Everett and was planning to send a sixth one up on its first (B-1) flight. This airplane was ZA435 (LN 131, B-2731) and is slated for delivery to Hainan Airlines sometime next month.  Boeing is appearing to make a huge last push to get at 5 to 8 deliveries done by end of the month and it does seem plausible that they can do it. If they were to do this then they can at least match the most 787 deliveries in one month if not surpass it. They would also deliver the 100th 787 to a customer.  We'll know by next Friday if they were able to attain this.

In closing let me leave you with one last thought:

Always be yourself. Unless you can be Batman.. Then be Batman.
— Ted (@OfficialTedSays) October 25, 2013

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787-9 flight testing picks up as production 787 flight test tempo increases ahead of planned deliveries

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Exactly 196 weeks or 3 years and 9 months after the first flight of ZA001 on December 15, 2009, Boeing successfully flew the next member of the 787 family, the 787-9.

Just a few days after the first 787-9 took to the air, the aircraft is packing on flight hours just a few days after taking its maiden flight.  Boeing is leveraging off the flight tests of ZB001's smaller sibling, the 787-8, to aggressively e 787-9's flight test envelope.  Because the aircraft is a  stretch of the 787-8 with the same wing and many of the same systems.  There are differences beyond the stretch of the airframe and these will be tested but given that Boeing has a ton of data already on the aircraft from the 787-8 testing they can pursue a higher flight rate.  It is still Boeing's plan to have a 6 month flight test/certification program.

There are still 2 more 787-9 in production.  The next one, ZB002, is almost complete.  ZB001 took 110 days from the start of final assembly on May 30 to first flight on September 17th.  If ZB002 takes the same amount of time (110 days) and using the July 12th date as the start of final assembly, this aircraft can possibly fly around October 30th.  However, I do expect that Boeing will apply lessons learned during the run up to ZB001's first flight to shorten that time.  It is entirely possible that ZB002 can fly around mid October.  Of course this is all dependent on finishing assembly activities and successful completion on ground testing.  ZB002 should roll out sometime in the first week of October if not earlier.

ZB021, the test aircraft that will be equipped with GE engines started final assembly on August 21st should roll out to the flightline around mid November and should fly by around early to mid December.

In the meantime Boeing is increasing the tempo of production flights has increased in the last few days as Boeing attempts to deliver around 10-12 787s this month.  So far 1 has been delivered.  We should see a good number of deliveries next week including 787s from the Charleston facility.

Lastly, I am attempting to document the 787-9 flight test program on a spreadsheet which is linked below.

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787 firing updated

The 787 firing order was updated to reflect 787 production up to and including L/N 180.  The customers aren't all that surprising but it does include the first 787-9 for Air New Zealand (ZB003, L/N 169) as well as three more 787-8s for Ethiopian.  Ethiopian is leaving open the possibility of increasing their 787-8 fleet after the final 787s are delivered in 2014.

Here's a rundown of L/N 162 to L/N 180:

ANA - 1
Air Canada - 2
Air India - 1
Air New Zealand - 1
British Airways - 2
China Southern - 1
Ethiopian - 3
Hainan - 1
ILFC/Aeromexico - 1
ILFC/Norwegian - 1
Jetstar (QANTAS) - 2
Norwegian - 1
Qatar Airways - 1
Royal Brunei - 1

With Boeing planning to increasing the assembly at aircraft 158 (ZA244, L/N 159, VT-ANP) by the end of the year.  This firing order should show aircraft that start final assembly through the end of February, 2014.

Boeing continues to prepare ZB001 (LN 126, N789EX) for first flight.  This should take place within the next 10 days.  The static pressure cone has been attached according to Matt Cawby.  Boeing has sent ZB002 (LN 133, N789FT) to get painted then will return to the assembly line where it will have more flight test equipment installed.  ZB021 (LN 139, N789ZB) is well into final assembly.  The first 2 aircraft will go to Air New Zealand after being refurbished though the final destination of the GE powered ZB021 is unknown.  It is rumored that the Mexican Air Force will get this aircraft to transport that country's leader and other government officials.

Lastly, Boeing still has to resume production flight testing though some flights have occurred for Charleston built 787s. Stay tuned for this month's flight tests to start within a day or two.

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Boeing rolls out 1st 787-9, deliveries increased last week.

Photo Courtesy of The Boeing Corporation

 

 

Boeing rolled out the first 787-9 to the flightline in preparation for first flight and the start flight and certification testing.  The program is expected to last approximately six months and would use three dedicated flight test aircraft: ZB001 (LN 126, N789EX), ZB002 (LN 133, N789FT), and ZB021 (LN 139, N789ZB) as well as one production standard aircraft that is not equipped with flight test gear: ZB197 (LN 146) which is earmarked for delivery to ANA.

Currently ZB001 is at the Everett fuel dock where it will undergo fueling tests and first start up of its APU.  Later it will move to the flightline for first engine start, gauntlet testing taxi tests and finally first flight.  I anticipate that ZB001 should be flying in about 2 - 3 weeks from now depending on how the other testing goes.  Here's the text of Boeing's press release:

Boeing Rolls Out First 787-9 Dreamliner

Second member of the super-efficient 787 family on track

EVERETT, Wash., Aug. 24, 2013 /PRNewswire/ -- Boeing [NYSE: BA] has completed the first 787-9 Dreamliner. The second member of the super-efficient 787 family rolled out of the Everett, Wash., factory today to the flight line, where teams are preparing it to fly later this summer.

At 20 feet (6 m) longer than the 787-8, the 787-9 will extend the 787 family in both capacity and range, carrying 40 more passengers an additional 300 nautical miles (555 km). The 787-9 leverages the visionary design of the 787-8 such as its exceptional environmental performance — 20 percent less fuel use and 20 percent fewer emissions than similarly sized airplanes — and passenger-pleasing features.

With the second and third airplanes in final assembly, Boeing and the 787-9 are on track. First delivery to launch customer Air New Zealand is set for mid-2014.

In other production news, Boeing delivered 6 787s between Aug. 16th and Aug. 23rd.  Looking ahead o the last week of August they will certainly deliver at least 2 more (1 each to Japan Airlines and Hainan Airlines).  There is a possibility of delivering two more to Air India but these deliveries, which were expected to take place last week and were held up due to Air India's inability to find financing to complete the purchase, may be held even longer due to the aforementioned inability to secure bridge financing.  Boeing had hoped to deliver one more 787 to British Airways this month but due to technical issues which forced the cancellation of 2 attempts to carry out B-1 testing it is now doubtful that this aircraft can be delivered this month.  Boeing will, at the very least, finish up August with 9 deliveries possibly 11.

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Boeing paints and rolls out 1st 787-9

Images courtesy of the Boeing Company

 

Boeing released a statement and photo of the 1st 787-9 after completing the painting of the aircraft.  Boeing said that it had rolled the aircraft out of the paint hangar so all you plane spotters please get to Everett for more photos.  Hopefully it wasn't rolled back into one of the assembly hangars. 

 

This plane is complete in the time frame I had predicted a couple of months ago (roll out in late July) and I still expect that first flight should occur (barring any unknown unknowns) by late August to early September to kick off the 6 month flight test/certification program.  Boeing will be giving a briefing on the 787-9 flight test and certification program but they will be using 3 instrumented aircraft (ZB001, ZB002, ZB021) and a 4th production standard aircraft (ZB197) which will not be instrumented.

 

Here's Boeing's Press Release: 

 

First Boeing 787-9 Dreamliner Features New Boeing Livery

EVERETT, Wash., July 27, 2013 /PRNewswire/ -- Boeing [NYSE: BA] continues to make progress on the first 787-9 Dreamliner, which also has become the first 787 to don the new Boeing Commercial Airplanes livery. The airplane has just rolled out of the paint hangar.

This refreshed look for the Boeing family began with the 747-8 and evolved with the 737 MAX. The new livery retains many of the features of the original 787-8 livery, adding a prominent number on the tail to help distinguish among models within the same product family.

The 787-9 will complement and extend the 787 family, offering airlines the ability to grow routes opened with the 787-8. With the fuselage stretched by 20 feet (6 meters), the 787-9 will carry 40 more passengers an additional 300 nautical miles (555 kilometers), with 20 percent less fuel use and 20 percent fewer emissions than similarly sized airplanes. The 787-9 leverages the visionary design of the 787-8, offering the features passengers prefer such as large, dimmable windows, large stow bins, modern LED lighting, higher humidity, a lower cabin altitude, cleaner air and a smoother ride.

Boeing is on track to roll out and fly the 787-9, currently in final production, in late summer. First delivery to launch customer Air New Zealand is set for mid-2014.