Boeing talks 787 progress and possible 777 upgrade

Boeing Photos

Jim McNerney, speaking on Boeing’s earnings conference call, says that flight testing of the 787 is on track and that Boeing still plans to deliver the 787 as planned by the end of the year. The 787 just received its expanded Type Inspection Authorization (TIA) from the FAA which means that the certification flights tests will begin. While this will be the longest (and most important) phase of the test flight program it also means that a lot of the risk in the 787 program has been retired. Boeing says that the aerodynamic configuration of the 787 is now fixed and that there won’t be any need for changes in the shape of the aircraft. Now essentially the FAA has to collect data for them to be assured that the aircraft is safe to operate in regular passenger service.

Another 2,600 hours?

To date, Boeing has accumulated over 500 flight test hours on the 4 test airplanes (the final two should be in the air in late May and mid June). That leaves about 2,600 of flight test hours that need to be flown by the end of 2010. Boeing has said that while some of the flight test schedule margin has been eaten they would be able to gain some of that margin back because data collection on each flight has been greater than anticipated as well as maturity of the aircraft systems has proven to be better than anticipated. In order to fly the 2,600 flight hours by the end of November (allows Boeing to receive type certification and prepare the first 787 for delivery in December) they would need to fly the test fleet over 81 hours per week. Not an impossible task but they would need to start doing that now. However, as Boeing tests the aircraft and sees no needs for configuration changes in the aircraft or the systems. This has opened up contingency and because they are getting much more data from each flight and retiring more of the risk and certification requirements it will lessen the need for more flights to accomplish all the required tasks. As future flights are flown Boeing feels that they can do more on each flight than they anticipated which would mean that they could add to the schedule margin. This is certainly a huge positive for the program and means that when ANA receives its first aircraft, it should be a matured system. All in all there is a lot of confidence in the 787 program especially with the testing that has been done thus far and what they can accomplish by the start of the 4th quarter. The tentative schedule for the 787 test fleet is as follows: ZA001 - won't fly until early May; ZA002 - should fly around April 30th; ZA003 - should fly around April 27th, ZA004 - should fly soon.

777 or 787-10

One big development from yesterday’s earning’s conference is that Boeing may decide to do an update of the 777 instead of developing the 787-10. This could have plenty of advantages which include reduced development time, lower R& D expenditures as well as better performance vs. the 787-10 (and by extension the A350-900 and A350-1000). A decision on this may be made by the end of this year.

Saj Ahmad of Fleetbuzzeditorial.com has a great analysis piece on the 777 vs 787-10.

Improved 777 May Get Nod Ahead Of 787-10

Better Late Than Never – 787 Moves Up A Gear

Lastly, Flightblogger is in Florida freezing his b**t off with ZA003. Check it out here.

787 get expanded Type Inspection Authorization...Finally

Boeing Photo of ZA003 at Eglin Air Force Base


The FAA has given Boeing the expanded TIA (Type Inspection Authorization) for the 787 last night. This now means that Boeing and the FAA will undertake test flights and ground tests to certify the 787. Boeing is still planning for first delivery by the end of this year to ANA. Boeing also announced that ZA003 is in Florida to undertake extreme weather testing after flying 5 hours from Boeing Field to Eglin Air Force Base. Boeing also noted that the 78 test fleet has now exceed 500 test flight hours. I'm still trying to find out when flight test will start to take place with FAA inspectors and engineers aboard but I anticipate that it will be soon. Here's Boeing's press release.

News Release Issued: April 20, 2010 11:14 PM EDTBoeing 787 Flight-Test
Program Progressing
EVERETT, Wash., April 20 /PRNewswire-FirstCall/ -- The U.S. Federal Aviation Administration (FAA) granted Boeing (NYSE: BA) expanded type inspection authorization (TIA) today, clearing the way for its personnel to fully participate in future test flights and for the collection of required flight-test data. Initial TIA was granted Feb. 11, which supported the collection of flutter certification data.
The expanded TIA marks the FAA's confirmation that the airplane and team are ready to collect additional certification data. Boeing achieved the expansion by demonstrating the readiness of the airplane throughout a variety of speeds, altitudes and configurations.
"This TIA expansion is another significant step toward delivering airplanes to our customers. We remain on track to deliver the first airplane to ANA this year," said Scott Fancher, vice president and general manager of the 787 program, Commercial Airplanes.
In addition to receiving expanded TIA, Boeing finalized the aerodynamic configuration of the 787.
"We have completed sufficient testing to decide that no additional changes to the external lines or shape of the airplane are required," said Fancher. "Having an airplane match its expected performance with so few changes is rare and speaks to the maturity of the design."
The 787 flight-test fleet logged its 500th hour of flying April 16. On Sunday, ZA003, the flight-test airplane outfitted with interior elements, landed in Florida, where it will go through extreme weather testing at McKinley Climatic Laboratory at Eglin Air Force Base.
Boeing released two videos highlighting flutter and ground effects testing. These videos feature commentary by the pilots and the chief project engineer and are available on http://www.boeing.com/ and http://www.newairplane.com/.

Flightglobal had picked up this story and you can read their article here. Fligtblogger also has a post on his blog about the TIA.

Flightblogger: Boeing 787 granted Type Inspection Authorization

A350 schedule slips

Aviation Week revealed that the start of final assembly as well as the first flight date for the A350-900 has slipped by three months. Airbus is not slipping the entry into service date and it is still unclear if there are any other possible strains to the schedule at this point.

Aviation Week attributes the delay to more time needed to finalize some of the detail design of the aircraft as well as other areas that needed more time. Final assembly is now due to start at the end of 3rd quarter 2011 (as oppose to end of 2nd quarter of 2011) with first flight due to take place during the third quarter of 2012 (vs. 2nd quarter of 2012). EIS is still scheduled for mid 2013.

Airbus is still struggling with weight issues on the airplane and have embarked on an aggressive weight reduction effort. Still it is tool early to say that the first delay is any indication of a trend of delays that may occur. Here's Aviation Week's article:

Airbus Delays A350 Final Assembly

The Aviation Week article confirms the belief of many in the industry that the A350 will be inevitably be delayed though there is still much discussion over the length of the delay. The fact that delays are being taken now as opposed to later in the program is not a good thing. Here's a an article by Saj Ahmad written about 3 months ago warning of the delays to the A350:

Airbus A350XWB Weight Grows As Pressure On Schedule Mounts

ZA001 to ZA004, what's happening

The 787 test flight fleet seems to be taking a break from flying...at least a few of the airplanes.

ZA001 - is in a pre-certification layup where it is also getting the Wedge 5.5 software upgrade which is already loaded on ZA004 and ZA002. So far it is not scheduled for any flights in the next three weeks.

ZA002 - also in a lay up but I'm not sure for what.

ZA003 - is curently being frozen into an ice cube in warm and sunny Florida.

ZA004 - will continue flying though I'm not sure when it is scheduled to go up next.

Still no word on the TIA though I'm hearing a rumor that it will issued this week.

On the move

It was moving day for engineers and other flight test personnel in both the 787 and 747-8 programs.

First, ZA003 flew to Eglin Air Force Base in Florida, the first cross country trip for the 787 to perform cold soak testing the the McKinley Climatic Laboratory. The aircraft will easily fit into the hangar sized for a C-5 Galaxy transport and will be subject to temperatures as low as -65 degrees Fahrenheit. The plan is for ZA003 tho be there until April 27th after which it will fly to either San Antonio, Tx. or Yuma, Az. for hot weather testing.

Second, RC521, the second 747-8 flew to Palmdale, Ca. where it will spend most of its test flight life. The aircraft first made a short flight to Moses Lake, Washington from where it proceeded to fly to Palmdale. Boeing says that the other two 747-8s will join this airplane in the coming weeks. Here is Boeing's press release on the 747-8's move to Palmdale:

Boeing 747-8 Freighter Begins Flight-Test Operations in Southern California
PALMDALE, Calif., April 19 /PRNewswire-FirstCall/ -- The second Boeing (NYSE: BA) 747-8 Freighter, RC521, landed in Palmdale, Calif., today, marking the beginning of a planned transition of 747-8 Freighter testing to Southern California. The more than four-hour flight from Boeing Field in Seattle included testing on avionics and cruise performance.

"Taking the airplane to Palmdale is a big step," said Mo Yahyavi, vice president and general manager of the 747 program. "The team is focused on ensuring a seamless transition into the next phase of the flight-test program as we prepare to expand testing of the 747-8 Freighter's performance characteristics."

The airplane will be stationed in Palmdale for the majority of its scheduled flight-test program. The crew will conduct several tests on the airplane with fuel-mileage and
engine-performance testing as key focus areas.

"Palmdale provides an excellent test environment for the 747-8 Freighter," said Andy Hammer, 747 test program manager. "It allows us to take full advantage of one of the world's premier experimental test flight facilities and the excellent weather conditions to meet our flight-test requirements on the road to obtaining our amended type certification."

A contingent of employees has been stationed at Palmdale for the testing, including flight-test engineers and the support personnel who prepare the airplane for each day's flights. In the coming weeks, the two other 747-8 airplanes in the flight-test fleet will join RC521 in Southern California.

The entire flight-test program calls for the three airplanes to perform a total of about 3,700 hours of ground and air testing. The first 747-8 Freighter delivery to Cargolux is planned for the fourth quarter of this year.

ZA003 headed cross country to Eglin Air Force Base

The third Dreamliner, ZA003, is at this moment flying to Eglin Air Force Base to take part in cold soak tests at the USAF's McKinley Climatic Laboratory. The 787 flew out of Boeing Field at 7:08AM PST for the 787s first cross country flight which should take about 5 hours or so even though Flightaware shows a flight time of 45 minutes...we knew the 787 is supposed to be fast but c'mon!

Flightaware for BOE 3

Flightblogger had revealed earlier this week that ZA003 would perform cold soak test at Eglin Air Force Base. I'm not sure how long it'll be there and what temperatures it will exposed to but they will run the 787s systems to see how they act in the extreme cold though I'm guessing they wouldn't run the engines or APU inside the lab.

Boeing responds to Type Inspection Authorizaton questions.

Earlier I asked Boeing about the delay to the TIA for the 787. Specifically, why was it delayed (no answer on this), when they will expect to receive it and impact to the schedule. Here's Boeing's response:

We have not received TIA yet but we expect it very soon. We continue to
accomplish meaningful progress in flight test and the exact timing of this is
not impacting margin.

So the important thing to take away from this is that Boeing expects no schedule impact from the delay of issuance of the TIA. To review the Type Inspection Authorization is the FAA certificate which allows FAA engineers and inspectors aboard the 787 for the certification flights. The issuance of this certificate formally kicks of the certification test flights that Boeing is required to perform in the presence of FAA personnel and represents the bulk of the test flight program. When James Albaugh spoke at the JP Morgan conference last month he had said that they expect the TIA by the end of March. He also said that Boeign had eaten into some of the margin in the order of 4 to 6 weeks.

It was expected that Boeing would have had the TIA by mid February but that was delayed to end of March (thus losing about 6 weeks of margin. The fact that Boeing is saying the additional delay to the TIA will not impact schedule margin means tha they have some sort of remediation planned to keep the certification test program on schedule.

Four Months In...787 Flight Testing Update

Four months after ZA001 embarked on its first flight the 787 test flight fleet continues to rack up flight test hours across four airplanes. Some of the milestones that were completed over the last month include:

• Completion of ground effects testing in Victorville, CA by ZA002
• Completion of flutter testing by ZA001
• Achieved 15% of total flight test hours
• ZA001 flies over 300 flight test hours
• ZA002 flies over 100 flight test hours
• ZA004 flies Wedge V5.5 service ready software
• Successful completion of the ultimate load test to 150% of maximum load on ZY997

One notable achievement that was supposed to be achieved during the past month was the issuance of the Type Inspection Authorization (TIA) by the FAA but as of today it still has not been issued. Word is that ZA002 needs to finish testing of the latest version of the flight control software before the FAA can issue the TIA. The issuance of the TIA may occur on April 16th though I am taking that date with a grain of salt. Still if it is issued tomorrow it does represent another 2 week slide in the test schedule thus eating up a total of 2 months of the schedule margin that Boeing allowed for itself. This may indicate that certification would not be given until early to mid December. I'm still waiting to hear from Boeing regarding the TIA.

As of April 14th, Boeing has flown 486 flight test hours spread across 164 test flight. The average flight has lasted about 2 hours and 58 minutes. The average flight utilization continues to decrease. In March it was 2.91 hours per flight and half way through April it is down to 2.65 hours per flight.

In order for Boeing to certify the 787 by early December (33 weeks), the 787s would have to fly over 2,600 flight hours which would equate to over 79 flight test hours per week. I speculate that the reason for the low number of flight test hours is the need to get the TIA from the FAA so that the real certification flight testing can commence. This seems to be the long pole in the tent at this point.

As far as ZA005 and ZA006, the GEnx powered aircraft maybe delayed even further though no reason has been given. ZA005 might be delayed to May 24th and ZA006 won't fly until June 21st.

Production is continuing with the 21st 787 entering final assembly. The 22nd 787 will start final assembly in about 10 days. Saj Ahmad of fleetbuzzeditorial.com has a great take on the the availability of early 787 delivery slots and their value in the market place. QANTAS and Virgin Blue are looking for early delivery slots with the former already having the aircraft on order and the later having converted to firm 777-300ER to options and possibly looking for early delivery slots for the 787. Read Saj's article here:

Fleetbuzzeditorial.com : Boeing 787 Slots Become Sudden Precious Commodities

Neil Armstrong blasts President's Space Plan

Neil Armstrong, an astronaut who prizes his privacy above all else, has publicly come out against President Obama's plan for NASA. In a letter that was published on MSNBC.com, he called Obama's decision to cancel the Orion spacecraft "devastating" to US Human Spaceflight.

Armstrong's Letter

The letter was signed by Armstrong, Gene Cernan, Apollo 17 commander and Jim Lovell, Apollo 13 commander. Many within NASA as well as outside of NASA have come out against Obama's plans which cancels the majority of US Human Spaceflight and put more money in an elaborate R & D program with no end result or ultimate destination as well as an extension of the ISS mission to 2020.

In response to the mounting criticism of his space plan, MSNBC reported that Obama is willing to revive development of Orion but for use as an ISS lifeboat which would launched unmanned and autonomously docked to the ISS for use an emergency escape vehicle and nothing else. The lifeboat Orion would have minimal systems to act as only a rescue/reentry vehicle and would not have any of the needed equipment/systems for lunar or Martian missions. Also Obama would accelerate the development of a heavy launch vehicle though without a capsule to place atop this HLV and no destination to which to send a payload, one has to wonder what it will be used for except for launching large satellites.

MSNBC: Obama revives capsule from cancelled program

MSNBC: First Moonwalker blasts Obama's Spaceplans

While this is a small step forward it still is not enough. There is still no destination, and there is still no means of reaching low Earth orbit let alone the moon even with the lifeboat Orion. Can the lifeboat Orion still designed with eventual missions to the moon and Mars in mind? Yes but again there is no commitment on part of the administration to go that far. The criticism by Neil Armstrong is certainly going to weaken the any leverage that Obama may have in Congress to get his vision for NASA passed. Tomorrow the President will visit KSC to make an announcement of his plans for NASA.

Flightbloggers 787 updates

Jon Ostrower aka Flightblogger had a couple of cool (one literally) posts that is 787 related.

The first one dealt with the paint scheme for JAL's first 787 which is currently in final assembly. The color scheme is based from drawing submissions from local children. Check it out:

Flightblogger: 1st JAL 787 livery

The 2nd post is concerns cold soak testing for the 787. Flightblogger says that ZA003 may be flying soon to Elgin Air Force Base's McKinley Climatic Lab on the Florida pan handle to conduct cold soak testing. Moreover, ZA003 might be departing for the cold soak testing as early as April 18th (next Sunday). As part of the required certification testing, the aircraft must be able to withstand temperatures of around -40 to -50 degrees Fahrenheit.

Flightblogger: Answering the 787 cold soak question once and for all

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.

Airbus delays A380 delivery to Korean Air

In a potential setback to Airbus' plans to deliver at least 20 A380s to customers in 2010, Airbus is delaying delivery of Korean Air's first A380 from 4th quarter of 2010 to the 2nd quarter of 2011 according to Businesweek. The reason is nebulously attributed to production delays though Airbus has been continuously plagued by production problems.

What is troubling is that the delay in delivery is potentially up to 6 months and it is for an airplane that is scheduled to be delivered 8 months from now. One has to wonder about the knock on effects on the A380 delivery schedule as well as the nature of the delay. Another question is what about delivery of A380 for the remainder of this year? Through the end of February, 2010, Airbus has delivered 3 A380s and is planning a production increase to take hold later this year. Currently Airbus is delivering 1 A380 per month and that plan should hold until mid year when the output is to increase to 2/month.

With this latest news, those plans maybe in doubt.

Businessweek: Airbus postpones 1 A380 delivery to Korean Air

Here's a commentary of the A380 production woes by Saj Ahmad at Fleetbuzzeditorial.com:

Fleetbuzzeditorial.com: Shoot the dog (part 4)

Boeing declare success on ultimate load test

Boeing says that last weeks ultimate load test were success after thoroughly reviewing the data. This means that Boeing has cleared a major certification hurdle for the 787 and confirms that the side of body fix did its job. Here's Boeing press release on the test results:

News Release Issued: April 7, 2010 1:49 PM EDT

Boeing Confirms Success on 787 Wing, Fuselage Ultimate Load Test

EVERETT, Wash., April 7 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) announced today that all test requirements were successfully met during the 787 Dreamliner’s ultimate load wing and fuselage bending test. This follows a thorough analysis of the results from a test on the 787 static test airframe.

“Successfully completing this test is a critical step in the certification of the 787. This is further validation that the 787 performs as expected, even in the most extreme circumstances,” said Scott Fancher, vice president and general manager of the 787 program for Boeing Commercial Airplanes.

On March 28, loads were applied to the test unit to replicate 150 percent of the most extreme forces the airplane is ever expected to experience while in service. The wings were flexed upward by approximately 25 feet (7.6 meters) during the test and the fuselage was pressurized to 150 percent of its maximum normal operating condition.

In evaluating the success criteria for the test, Boeing specialists have been pouring over the thousands of data points collected during the test to ensure that all parts of the airplane performed as expected.

“The airframe performed as designed and retained the required structural integrity. These results continue to validate the design of the 787 as we move toward certification,” explained Fancher.

Video of the static test can be found at the 787 flight test Web site at www.boeing.com and www.newairplane.com.

Air Transport World: Boeing targetting end of November 2010 for first 787 delivery to ANA

According to Geoffrey Thomas of Air Transport World, Boeing is saying that first delivery to ANA is on track for the end of November. Further, he reports that the FAA will issue the TIA (Type Inspection Authorization) for the 787 this week. I had reported that it should be forthcoming today and I am still awaiting word on that.

Geoffrey Thomas : Boeing says 787 flight test program on track for November first delivery

Yesterday, Boeing reported that it had completed the first 787 maintenance training class for ANA maintenance personnel. The class consisted of 10 mechanics who will be maintaining the 787 as well as 2 regulator from the Japanese Civil Aviation Bureau. Here's Boeing's press release:

News Release Issued: April 6, 2010 5:27 PM EDT

Boeing Completes First 787 Dreamliner Maintenance Training Class

EVERETT, Wash., April 6 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) today announced that it has completed the first maintenance training class for the 787 Dreamliner. The class consisted of 10 mechanics from 787 launch customer ANA (All Nippon Airways) and two regulators from the Japan Civil Aviation Bureau (JCAB).

The mechanics, who completed the training last week, are the first of 150 ANA mechanics to be trained by Boeing over the next seven months. They spent more than 30 days learning how to maintain the world's most advanced commercial jetliner, including 20 days of theoretical training, two days of engine runs and taxi testing, five days of practical training and five days of troubleshooting exercises. To conclude the training, students conducted component identification exams on production airplanes, as well as troubleshooting exams in the full flight simulator.

To support the all-new 787, Boeing Training & Flight Services, a division of Commercial Aviation Services, Boeing Commercial Airplanes, has developed an all-digital, Internet-based teaching system for maintenance training, along with training tools that connect real-time to a virtual airplane and airplane systems.

"Getting our mechanics trained and prepared is essential to being ready to take delivery of the airplane later this year," said Michihide Kono, vice president of Engineering and Maintenance for ANA. "This is an important milestone for our ANA team and we are delighted to see the continued progress on the program."

The curriculum is designed to focus on performance-based training that incorporates real-world simulated maintenance scenarios for a more immersive training experience.

"The use of personal tablet computers, interactive computer-based training,
three-dimensional images and desktop simulation makes it possible to deliver training more efficiently," said Sherry Carbary, vice president of Boeing Training & Flight Services, Commercial Aviation Services, Boeing Commercial Airplanes. "Our team is committed to providing our customers with the resources and tools they need to be successful."

The 787 comes with digital tools and databases that replace volumes of printed materials. The graphic and textual database has point-and-click features for more details, allowing mechanics to navigate through documents quickly to get the information they need to do their jobs.

"This milestone is another important step along the way to being service-ready," said Mike Fleming, director of 787 Services and Support, Boeing Commercial Airplanes. "Our goal is to make entry into service a seamless experience for our customers."

Fifty-seven customers around the world have ordered 866 787s since the program was launched in April 2004, making the Dreamliner the fastest-selling new commercial jetliner in history. Delivery of the first 787 is planned for the fourth quarter of 2010.

Boeing Charleston Plant starts putting up steel columns

Boeing Photo

Construction Workers have started to put up steel columns for the first Boeing assembly plant outside of Washington State. The plant is due to be completed in the summer of 2011 with final assembly of the first 787 to begin in July 2011, 15 months from now. The first delivery of a North Charleston assembled 787 is scheduled for the first quarter of 2012, about two years from now.

Here's Boeing's Press Release:

Boeing 787 Final Assembly and Delivery, Charleston Facility Taking Shape

First steel column marks visible progress

NORTH CHARLESTON, S.C., April 5 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) took another visible step toward full 787 Dreamliner production Monday by placing the first steel column for its Charleston 787 Final Assembly and Delivery facility.

"This new facility will expand our production capability and strengthen the 787 program as we work toward rate," said Marco Cavazzoni, vice president and general manager of 787 Final Assembly and Delivery, Charleston, Boeing Commercial Airplanes. "And that reflects our commitment to our customers, our team and our South Carolina community."

Today, Boeing Charleston fabricates, assembles and installs systems for 787 aft fuselage sections and joins and integrates midbody fuselage sections from other structural partners. With the new, 1.2-million-square-foot (92,903-square-meter) building, Boeing will perform final assembly and deliver 787s from North Charleston to customers around the world. Construction on the new facility is on schedule, with production due to begin in July 2011. Boeing will deliver the first 787 built in Charleston in first-quarter 2012. To date, 90 percent of the Boeing direct-contracted dollars for the project have been with South-Carolina-based companies.

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-seven customers around the world have ordered 866 787s since the program was launched in April 2004, making the Dreamliner the fastest-selling new commercial jetliner in history.

The steel construction should be completed in about 6 months barring any issues such as weather. A couple of the local Charleston Media outlets covered the story:

Post and Courier : Boeing's Big Expansion Advances

WCBD-TV : Big Day for Construction of Boeing Plant in North Charleston

Update on 787 Flight Test

So I got a few words on the 787 flight test progress.

The first bit of news is that Boeing should get the Type Inspection Authorization (TIA) around the middle of this week. This is tentative but has shown up on the 787 master phasing plan. We'll know more by the 7th.

Both ZA003 and ZA004 were supposed to fly this past weekend but ZA004 had some minor APU issues so it's flights this past weekend were cancelled. No word on ZA003 flight. These planes could fly as early as today (April 5).

Lastly, ZA002 could be back in the air between today and Wednesday (April 7th). ZA005 is schedule to fly by May 16th and ZA006 should be in the air by June 6th.

Stay tuned in the ever changing program.

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.

Boeing confirms success of 787 Ultimate Load Test

Boeing Photo

Hours after conducting the ultimate load test, Boeing announced that the test has been completed successfully based on preliminary examination of the data. It will be a few more weeks of detailed analysis by Boeing structural engineers. The wings were deflected to 25 ft high during the test. Once the data is analyzed by Boeing it will be sent to the FAA as part of the certification program. This is a huge hurdle that Boeing overcame especially in light of the side of body issue that was revealed over 6 months ago. Here's Boeing's press release:

Boeing Completes Ultimate-Load Wing Test

EVERETT, Wash., March 28, 2010 – Boeing today completed the ultimate load wing up-bending test on the 787 Dreamliner static test unit. During the testing, loads were applied to the airframe to replicate 150 percent of the most extreme forces the airplane is ever expected to experience while in service. The wings were flexed upward by approximately 25 feet (7.6 meters) during the test.

Initial results of the ultimate load test are positive. More extensive analysis and review are required before the test can be deemed a success.

“The test program has been more robust than any conducted on a Boeing commercial jetliner,” said Scott Fancher, vice president and general manager of the 787 program, Boeing Commercial Airplanes. “It has taken countless hours of hard work by the Boeing team and our partners to work through the static test program. Everyone who has been involved in this effort over the past several years should be very proud of their contributions to ensuring the safety of the 787 Dreamliner.

“We are looking forward to the technical team’s report on the details of the test results,” said Fancher. It will take them several weeks to work through all of the data.

During each second of the more than two-hour test, thousands of data points were collected to monitor the performance of the wing. Key data points are monitored real-time during the test, but all of the data will be evaluated in the weeks ahead.

The next major milestone is the issuance of the Type Inspection Authorization (TIA) that will kick off the formal certification of the 787 by the FAA with their inspectors and engineers flying on board the 787 during the certification test flights. That is expected any day now, perhaps as early as tomorrow.

Guy Norris, Flightblogger and Saj Ahmad also posted info on the 787 ultimate load test. Here are the links for your reading pleasure:

Guy Norris: Wing ultimate load test complete on 787

Flightblogger: Confirmed: ZY997 completes 150% ultimate wing load test

Saj Ahmad: Boeing 787 Wing Test Milestone Completion

787 ultimate load test to be conducted today

Boeing Photo

UPDATE (6:21 PM on March 28th): Flightblogger just tweeted that the test has occured and that indications are that the wing had passed the 150% ultimate load test with no funnies. Good news!

Boeing has scheduled the ultimate load test for the 787 wing today, March 28th. the test was to occur between 10 AM and 12 noon Pacific Time. Since it is past that time there is still no word on if the test was conducted and the results (if any).

In order for the test to be undertaken today, Boeing cleared buildings 40-22 (747 assembly), 40-23 (static test) and the 40-24 buildings of all personnel except for the test engineers that are sequestered in a "bomb shelter" in building 40-23. This is in case the wing fails before it reaches the 150% load threshold. Boeing doesn't plan to break the wing above the 150% threshold.

I am still waiting to hear about results but until then here's a great article from Bloomberg about the 787 ultimate load test.

Bloomberg: Boeing plans critical test on Dreamliner today

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

Flightblogger: Ultimate Load Test to be conducted on March 28th

Boeing Photo

An important test for the 787, called the ultimate load test, will be conducted by Boeing on the static test air frame on March 28th. This test is important as it will validate Boeing's wing design to withstand 150% of the limit load that the wing will experience. This test is required by the FAA as part of the certification of the aircraft. Passing this test means that a huge hurdle in the design of the aircraft has been passed.

This test comes on the heels of the side of body fix that was needed on all the 787s to strengthen the join between the wing and the center wing box of the airplane. Without the fix, Boeing would have failed the ultimate load test. It had previously passed the limit load test though there was some delamination of the composite material.

The test will be conducted ZY997 which is the static test air frame.

Flightblogger article

Flightblogger 787 Flight Test Review

Flightblogger has put up an update along with pictures and video of the current 787 progress to date. In it he describes what has been done and what is in store for the immediate future with the 6 test airplanes as summarized below:

ZA001 : Completed flutter testing and is now commencing high speed stability and control testing.
ZA002 : Still in Victorville after completing ground effects testing but is due to return to Boeing Field tomorrow, March 23rd.
ZA004 : Will finish up flight testing of the version 5.5 service ready software today, March 22nd and then will go into a period of extended ground testing
ZA003 : Going through a planned post first flight layup. I'm not sure when she's due to fly again.
ZA005 and ZA006 : Still at Everett Field with ZA005 due to be moved to paint shop soon for aqueous wash of it's fuel tanks. Word I've gotten is that ZA005 won't be in the air until around May 8th and ZA006 won't fly until around June 4th. These are estimates by the way.

Flightblogger: 787 Flight Testing Month 3 (Plus 7)

Lastly, there's a great article taking a look inside the 787 telemetry room at Boeing Field. The article is authored by Jason Paur of Autopia. This is great for those of us who don't really understand the goings on of flight testing of a new commercial airliner.

A Look Inside the Brains of Boeing 787 Flight Test

Boeing Completes Flutter and Ground Effects Testing on the 787

Boeing Photo

Boeing announced (through Randy Tinseth's blog) that they had completed flutter and ground effects testing. Boeing engineers had looked at the data from flutter tests and the results are as their model had predicted. This data is being submitted to the FAA as part of the requirements for the TIA, the Type Inspection Authorization.

The TIA will allow FAA inspectors and engineers on board the 787 for certification testing which starts after the issuance of the TIA. There is no word on when Boeing will receive the 787 TIA but it is expected before the end of this month.

Boeing had expected to complete this phase of the flight test program by mid February. Thus they are about a month and a half behind but still have some margin left in the flight test program schedule.

Certification testing is the longest part of the test flight program and will probably last until October or November depending on progress.

Here are a couple of links on this news:

Autopia: Boeing 787 Completes Critical Flutter Testing

Randy's Journal : Flutter and ground effects

Three Months In

Boeing Photo

Three months into 787 flight testing Boeing is slowly ramping up the number of airplanes to the test flight fleet with the recent addition of ZA003 to the test flight program yesterday. However, through three months since ZA001 took flight, the program has accumulated just shy of 307 flight hours spread across 101 flights and 4 test airplanes.

Boeing has indicated that the program will need 3,100 flight hours (3,700 ground test hours) for full testing and certification. Additionally, Boeing Commercial Airplane Group chief, James Albaugh, said that by mid year the test flight fleet will be flying about 90 hours per week on average.

Given the 307 hours already flown (not even 10% of the total needed) three months in, Boeing would need to fly another 2,793 hours. Assuming another 8 months for those flight test (taking us to mid November, 2010), then Boeing would need to fly about 350 hours per month on average or over about 88 hours per week across the test flight fleet.

Mind you that right now there are 4 test airplanes in the fleet with some planes flying less hours than others given the flight test assignments for each airplane. For example, ZA003 will log significantly fewer hours in the air due to the cabin testing it will be doing versus ZA001. Thus much of the flight testing would fall on ZA001, ZA002, ZA004 and the unflown ZA005. ZA005 won't be flying until early May and ZA006 won't be flying until early June according to sources. Thus if Boeing plans to deliver by the end of the 4th quarter (they would need time to flight test the production airplanes as well as incorporate any changes that are needed), they would need to get more aggressive with flight testing as they are flying, on average, about 96 hours per month granted that flight testing has ramped over of the months. Boeing has achieved 100 test flights in the 3 months since ZA001's first test flight.

In December, the 787 flight test program logged 18 hours and 57 minutes across 5 flights. That averages about 3 hours and 47 minutes per flight.

In January, the flight test team logged 47 hours and 23 minutes across 13 flights. That is an average of 3 hours and 38 minutes, slightly lower than December.

In February, the 787 was flying 136 hours and 40 minutes across 46 test flights. That is an average of 2 hours and 58 minutes of flying time which is dramatically lower than January.

Through the first 15 days of March, the test flight fleet has flown 103 hours and 50 minutes over 37 flights. This equates to an average of 2 hours and 49 minutes per flight....even lower than February.

Thus utilization of the test flight fleet has been decreasing since first flight. If Boeing hopes to certify and deliver the 787 then the aircraft test flight utilization has to dramatically increase.

Busy Day for Boeing Flight Test....Again!

Boeing Photo
Boeing Flight Test Group is getting areal workout today by sending the 4th 787 (ZA003) and the 2nd 747-8F (third 747-8 built) into the air today. First up was ZA003. This aircraft, which will test the aircraft's cabin systems and is equiped with a representative cabin layout, took off from Everett Field at 10:52AM PT and flew over eastern Washington State. ZA003 landed at Boeing Field about 1:52PM PT. It had been airborne for a little over 3 hours.

Boeing has released a press release about ZA003's first flight. Here's the press release:

News Release Issued: March 14, 2010 7:22 PM EDT

Fourth 787 Joins Boeing Flight-Test Fleet
EVERETT, Wash., March 14 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) has added the fourth 787 Dreamliner to its flight-test fleet with the completion of the first flight of ZA003. The airplane departed Paine Field in Everett, Wash., at 10:55 a.m. (Pacific time) and landed at 2:01 p.m. at Boeing Field in Seattle.

Captains Ray Craig and Mike Bryan piloted the airplane on its three-hour-and-six-minute flight. ZA003 is the final 787 with Rolls-Royce Trent 1000 engines to enter the flight-test program.

"We've done a significant amount of ground testing on the new systems on ZA003 in preparation for first flight. Engineering, manufacturing and flight operations have really pulled together as a team to enable first flight," said Craig. "It has been very rewarding to watch the Boeing team pull together in support of this milestone."

ZA003 is the only 787 in the flight test fleet that will include elements of the passenger interior features including cabin and crew support systems. The 787 is introducing new passenger amenities and provisions for a more comfortable flying experience. Among the new features are improved lighting, bigger stowage bins, larger windows with electrochromatic shades and redesigned lavatories with easier access.

In addition to demonstrating that the interior meets certification requirements, ZA003 will be used to conduct tests on systems, noise performance, flight-deck operations, avionics, electromagnetic effects, high-intensity radio frequency response and extended operations (ETOPS).

"The Boeing team is doing great work. We've established a good pace of accomplishment on the program," said Scott Fancher, vice president and general manager of the 787 program, Boeing Commercial Airplanes. "The priorities are clear and the entire team is focused."
In the meantime, while ZA001 and ZA002 have been flying test flight, ZA004 has been used as a ground test article, for the time being, for the "service-ready"version of the 787 software, according to Flightblogger. The software includes tweaks to correct issues found during test flights of the 787. The testing that ZA004 is required by the FAA prior to the issuance of the Type Authorization Inspection certficate that will allow FAA inspectors and engineers on the 787 for certification test. According to Flightblogger, ZA004 should return to the air by tomorrow and will do some more ground testings followed by more flight testing at Victorville. Additionally, Flightblogger revealed that ZA005 and ZA006 should be flying by the end of April.

Service-ready 787 software tested ahead of TIA

Guy Norris also wrote a great update on the 787 and 747-8 flight testing progress to date:

Guy Norris' 787 and 747 Flight Test Update


ZA003 take off form Everett Field - Video Courtesy of Matt Cawby


787 ZA003 First Flight from Liz Matzelle on Vimeo.

Boeing Photo
Later this afternoon, RC522, the third 747-8 built took offf from Everett for it's first test flight and the second 747-8 to fly. The aircraft is registered N50127 and took off at 3:55PM PT. As of 6:06PM PT, the aircraft is still airborne though it does look like it's going to land at Boeing Field. I'll try to find out more about this if I can. the 747-8 test fleet is to be based out of Moses Lake Airport,initially and later on will be based out of Palmdale, California. It's sistership, RC501 flew a brief test flight this afternoon and the 2nd 747-8 (RC521) will fly tomorrow, March 15th, from Everett Field. Here's Boeing press release (according to which, Capt. Kirk was at the controls:

News Release Issued: March 15, 2010 1:21 PM EDT

Second Boeing 747-8 Freighter Completes First Flight

EVERETT, Wash., March 15 /PRNewswire-FirstCall/ -- A second Boeing (NYSE: BA) 747-8 Freighter, RC 522, successfully completed its first flight Sunday evening. The airplane took off from Paine Field in Everett, Wash., for a two-and-a-half-hour flight and landed at Boeing Field in Seattle.

Captain Kirk Vining was at the controls for the flight, with Rick Braun operating as co-pilot and Joel Conard serving as systems operator. The airplane reached an altitude of 27,000 feet (8,230 m) and an airspeed of 240 knots, or about 276 miles (444 km) per hour. It took off at 3:57 p.m. PDT and landed at 6:25 p.m.

"The airplane performed well on its first flight," said Andy Hammer, test program manager for 747-8. "It was a good start to a demanding flight-test program for this airplane."

This is the second of three 747-8 Freighters being used in the flight-test program. Each
airplane will be used for a specific set of tests, with this airplane focusing on community noise, environmental control systems and extended operation performance standards.

The airplane will begin its flight-test program at Boeing Field before transitioning to Palmdale, Calif.

747 and 787 flight test update

So a couple of things coming out.

ZA003 first flight window opens at 10AM PST on Sunday March 14th (I'll be away skiing so I won't be able to cover it).

ZA004 was expected to return to flight tests this week but now it's been pushed back due to more ground tests at Boeing Field. Still no word on when it'll return to the air. As you may recall, after first flight ZA004 is spending some time on the ground for flight test equipment installation and calibration as well as for further ground tests. Boeing really needs to get this airplane back in the air soon given the testing that has been assigned to it.

Lastly, Randy Tinseth got up two nice posts on it, one on ZA002 and the testing at Victorville as well as one one the747-8 flight testing. The last two 747-8F will both be in the air in the next five days.

Randy's Journal: Hotel California

Randy's Journal: 13 flights, 33 hours

Forbes is bullish on Boeing

Forbes put out an article today which is bullish on Boeing. The cite not only that they expect Boeing to reap $18 billion on revenues from the 787 4 years from now but the revenue stream from the 747-8 program will also be strong.

Forbes: Boeing Now Boarding

Boeing: 747-8F completes initial airworthiness test

Boeing Photo

Boeing announced that the first 747-8, RC501 has completed the initial airworthiness tests. This now means that flight test engineers can fly aboard as well as allowing the other two test flight airplanes to fly which is expected on March 15th and March 17.

Here's Boeing's Press Release:

News Release Issued: March 11, 2010 8:00 AM EST

Boeing 747-8 Freighter Achieves Initial Airworthiness Milestone

MOSES LAKE, Wash., March 11 /PRNewswire-FirstCall/ -- Boeing (NYSE: BA) has completed initial airworthiness testing on the 747-8 Freighter. This milestone enables test engineers to be on board during future flights and allows the remaining two 747-8 Freighter test airplanes to begin flight test.

"The airplane is performing as expected in the initial stages of flight test," said Mo Yahyavi, vice president and general manager of the 747 program, Boeing Commercial Airplanes. "That's a tribute to the men and women who helped design and build this airplane."

Since the first flight in early February, the program has conducted 13 flights, achieving several key accomplishments. Pilots have taken the airplane to an altitude of 30,000 feet (9,144 m) and a speed of Mach .65. The program has completed approximately 33 hours of flying. Initial stall tests and other dynamic maneuvers have been run, as well as an extensive checkout of the airplane's systems. Five different pilots have flown the newest Boeing freighter.

"This is a critical milestone in our test and certification plan," said Andy Hammer, test program manager for the 747-8, Boeing Commercial Airplanes. "With the addition of the other two airplanes in the near future, the test program will ramp up significantly. We will expand the flight envelope and demonstrate the airplane's capabilities."

In the weeks ahead, the 747-8 Freighter will reach an altitude of more than 43,000 feet(13,106 m) and a speed of Mach .97. Subsequent testing will push the airplane beyond expected operational conditions.

Flight testing will continue in the months ahead. All told, the 747-8 Freighter test program calls for approximately 3,700 hours of testing using three test airplanes. First delivery is planned for the fourth quarter of this year.

Boeing has secured 108 orders for the 747-8, 76 of which are orders for the new freighter. Cargolux, Nippon Cargo Airlines, AirBridgeCargo Airlines, Atlas Air, Cathay Pacific, Dubai Aerospace Enterprise, Emirates SkyCargo, Guggenheim and Korean Air all have placed orders for 747-8 Freighters.

Some other 787 tidbits

Trying to get some more infomration on a slow new day today.

ZA001 will be taking to the air today for another flutter test flight today.

Matt Cawby reported in a post that ZA102 (LN 9) has finished its side of body modifications that were done in the Everett flightline tent.

Matt Cawby's 787 Update - March 9

This aircraft will be moved in the next couple of days to building 40-24 to one of the 767 slant positions on the 767 final assembly line to finish reassembly activities. The aircraft that is there now, ZA005 (LN 5) will be moved out to the flightline. Speaking of which, Dreamliner 5 and Dreamliner 6 won't be making their first flights until the 2nd quarter so that mean we won't see the GEnx-1B airplanes up until April at the earliest. ZA530 (LN 10) will be moved into the flightline tent to begin its side of body modifications.

ZA002 has landed in Victorville for a few weeks of flight testing then it'll be back to Boeing Field.

Here's Boeing's press release:

News Release Issued: March 9, 2010 3:59 PM EST

Boeing 787 Begins First Flight-Test Operations Outside of Washington

VICTORVILLE, Calif., March 9 /PRNewswire-FirstCall/ -- The second Boeing (NYSE: BA) 787 Dreamliner, ZA002, landed at 10:53 a.m. local time today in Victorville, Calif. This marks the beginning of the first flight-test operations outside of Washington state for the program.

The airplane will be stationed at Victorville for approximately three weeks. The crew will conduct ground effects testing among other activities.

During ground effects testing, the pilots fly the airplane very close to the runway to gather data regarding the aerodynamic effects and performance of the airplane during the takeoff and landing phases of flight. Quantifying this performance is part of the certification requirements for all new airplanes.

"Victorville's airfield is the former George Air Force Base," said Randy Neville, chief pilot for ZA002. "There is ample ramp space for parking and plenty of on-site facilities. There is a long runway and plenty of level, clear land along the approach to the runway. We can operate there without disrupting air traffic control or other commercial aircraft."

A crew of more than 150 employees will be stationed at Victorville while the airplane is there.These include the flight test engineers and support personnel required to prepare the airplane for each day's flights and to monitor performance and test equipment.

"Our confidence in the reliability of this airplane grows day by day," said Scott Fancher, vice president and general manager of the 787 program. "Taking the airplane out of state for the first time is a big step, but one we're ready for."

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

Repubic of Iraq orders 10 787-8

Today Boeing revealed the buyer of 10 787-8, purchased on Dec. 22, 2009, being the Govt. of Iraq. These airplanes will presumably be going to the state owned airline, Iraqi Airways. The airline is experiencing a renewal in light of some stability returning to Iraq and more projected demand for travel to Iraq as the US military leaves that country.

The order was listed on Boeing Order's and Delivery site:

Boeing's December 2009 order detail

Flightblogger: ZA002 going to So. Cal.

Flightblogger is reporting that ZA002 will fly to Victorville, Ca. this week as part of the 787 flight test program. The Southern California Logistics Airport (SCLA) is in the high desert of southern California and has a a long 15,000 ft runway and dry weather which would be ideal for Boeing to conduct flight testing.

It is not known when or how long ZA002 will beat Victorville or if other 787s will be joining it but the certification test program has the 787 test fleet making trips away from Boeing Field at times.

Flightblogger : Roadtrip! 787 heading for Victorville this week.

Through today's test flights, the 787 fleet has racked up slightly over 250 test flight hours across the three plane test fleet. ZA00 s expected to return to the air very soon (possibly by the end of this coming week) and ZA003 is expected to take to the air for the first time around March 14th. ZA005 should follow soon after that.

Continuing the roadtrip theme, Guy Norris at Aviation Week is reporting on his blog that Boeing is seriously considering sending the 787 AND the 747-8 to the Farnborough Air Show this summer. It would the first time since 1982 that two new Being Commercial Air products would be featured at the air show. Of course, all this hinges on how well the test program goes for both these airplanes.

Guy Norris: Show Time!

Guy also reports on the upcoming trip for ZA002 to California as well as updates on the rest of the 787 flight test fleet. Of note is that ZA003 will have it's two day gauntlet test this week. This would corroborate a flight test date of March 14 for this airplane.

Guy Norris : 787 Heads South

Dreamliner 3 to fly around March 14; BCA Chief Talks

Sources have told me that ZA003 should fly (penciled in) around March 14th and Dreamliner 4 should return to the skies within the next one week after installation of more flight test equipment. Meanwhile the 787 test fleet is still racking up the hours with yesterday's test flights pushing the total test flight hours to over 225. Dreamliner 1 go to as fast as 0.96M at 33,000 feet in a test flight conducted on March 3, 2010.

Seattle Times reporter Dominic Gates had a revealing interview with Boeing Commercial Airplane group head Jim Albaugh.

Here's the extended interview:


In it he says Boeing prefers to build its commercial airplanes in the Puget Sound region of Washington State but only if they can get labor peace from IAM and SPEEA. The prospects of labor unrest is what motivated Boeing to locate the second line to Charleston, SC. Also very revealing is that Boeing will now dial down the 787 business model for future aircraft programs and not outsource as much work as they did for the 787. This will include the design, testing and production of the wings. Boeing will return more of the engineering in house for parts of the aircraft such as flight controls, composite fuselage and the wings. The outsourcing was driven more by business decision making rather than engineers making those decisions.

You can read the entire article below:

Dominic Gates' Interview with James Albaugh

787 exceeds 200 flight hours; 18th 787 starts final assembly

As Boeing continues to pile on 787 flight hours, it has also started final assembly of the 18th 787 destined for ANA.

Dreamliner 1 continues to rack up the most flight hours and mos flights with 39 flights that has accumulated almost 138 flight hours through March1, 2010. The 787 test fleet has accumulated almost 210 flight hours.

Boeing also started assembly of Dreamliner 18 after line move yesterday. Look for Boeing to start assembly on LN 19 and LN 20 (I don't have the ZA numbers yet). The later aircraft is an important milestone as it is a new block point that incorporates weight saving measures in an effort to lower the weight of the airplane. The 787-8 is still overweight but Boeing still hopes to find further areas where they can take out weight as the flight testing progress.

Because of the addition of ZA004 to the test program, Boeing will have valuable data to finalize the design of the 787-9 which is the stretched version of the 787-8. The -9's wing will be the same as that of the 787-8 but Boeing is hoping that test flight information from ZA004 flight tests will yield important information when designing the 787-9. Flightblogger has a blog post up tonight describing the 787-9 progress to date. In the article he says that the first 787-9 will be designated ZB001 but will be LN 139.

Flightblogger: Driving Forward on the 787-9 design

Guy Norris also put up an update on the 787 flight testing as well as the 747-8 flight testing. Guy sasy that ZA001 has flown 11 flutter tests (now 12) while ZA002 continues with stability and control flight testing. ZA003 should also start the run up to gauntlet testing next week.

Guy Norris : 787 and 747 test update