Matt Cawby: Taxi tests planned for Thursday, June 25th, 2009

Matt Cawby posted on his blog that the first taxi runs should start on June 25, 2009. He also reported that the static pressure guide wire and cone was retracted into the tail of ZA001. Also ZA002 has started its APU.

Matt Cawby's Blog entry

Boeing Announces the start of final assembly on ZA100

Boeing has confirmed my earlier post from yesterday that ZA100, the 7th 787 to be built and the first production 787 for ANA has started final assembly. Here is Boeing's press release:

News Release Issued: June 17, 2009 6:32 PM EDT
Final Assembly Begins on First Boeing 787 Dreamliner for ANA
EVERETT, Wash., June 17 /PRNewswire-FirstCall/ -- Final assembly has begun on the first Boeing (NYSE: BA) 787 Dreamliner destined for delivery to launch customer ANA (All Nippon Airways) of Japan.

ANA and Boeing launched the 787 program with a firm order for 50 of the all-new composite jetliner. Deliveries are scheduled to begin in the first quarter of 2010.
Boeing and ANA celebrated the occasion with a traditional "Kagami wari" ceremony, the breaking open of a wooden "Taru" (sake barrel) lid with wooden mallets.
"This is a great day for the 787 team," said Scott Fancher, vice president and general manager of the 787 Dreamliner program. "In 2004, ANA demonstrated great faith in Boeing and the 787 by placing the largest launch order for any new airplane in Boeing history. Since then, the ANA team has been an integral part of developing the 787 family of airplanes.
"Speaking for our entire global 787 team, including our partners, I'd like to say we are honored by ANA's commitment to the Dreamliner," Fancher said. "We look forward to our continued partnership as we prepare the 787 to enter commercial service."
"Congratulations to Boeing on the start of the historic assembly of the first 787 Dreamliner for commercial flight," said ANA President & CEO Shinichiro Ito. "As the launch customer, we are delighted and excited to see the achievement of this milestone and to have worked closely together to reach this day. We look forward to the start of the 787 flight test program and delivery into our fleet next year."
The 787 Dreamliner has 865 orders from 56 airlines, making it the fastest-selling all-new jetliner in aviation history.
Pictured from left to right are: Kinichiro Suetsugu, manager - ANA U.S. Engineering; Takeo Kikuchi, general manager - ANA U.S. Engineering; Scott Fancher, vice president and general manager - 787 program and Mike Fleming, director of Services and Support - 787 program.
More information: http://www.boeing.com/commercial/787family/
Neg. K64723
Contact:
Mary Hanson
787 Communications
+1-206-898-4749
mary.hanson@boeing.com
SOURCE: Boeing
Web site: http://www.boeing.com/

787 Update from Paris, Day 2

UPDATE (06/16/2009; 10:50PM EST): A source has told me that final assembly on ZA100, the first 787 for ANA will start tonight in Everett.

Wow lots of news coming out about the 787 today so where to start?

Let's start with ZA001's road to first flight. I got a lot of the information from Guy Norris two 787 reports today.

Pat Shanahan gave an update on the status of Boeing's Commercial Product Development today in Paris. In the briefing he indicated that first flight could be a lot closer than the end of the month. Currently ZA001 is undergoing engineering tests that should lead up to a flight readiness review and then to final gauntlet which would after the review. Pat Shanahan also warned that there is no margin left in the testing and certification schedule so if there are problems that are uncovered during flight testing then that moves the entry into service to the right. Pat Shanahan also said that Global Aeronautica continues to be the weak link in the supply chain with the main issues being the travelled work as well as incorporation of the design changes.

So far ZA001 has completed flight control checks on June 16th and today are going through hydraulic systems checks today. Additionally, ZA002 which was rolled out to the flightline on Sunday has already completed its first fueling tests.

Guy's 29th 787 Update
Guy's 30th 787 Update
Aviation Week - ZA002 roll out

Highlighting the readiness of ZA001 to fly, Scott Carson told Bloomberg that ZA001could fly today if they wanted to. They won't fly it of course until they have gone through further tests but this illustrates the confidence that Boeing has in the 787 and the maturity of the systems that are loaded on the aircraft. He stated that the aircraft did much better than anticipated during the recently completed gauntlet tests.

Bloomberg's 787 article

From Flightglobal, Jon Ostrower confirmed what I had suspected a few days ago...the LCF flew in the main fuselage section for ZA100. This is the first production aircraft for ANA and was apparently delivered with a banner that read "Building with pride, the first 787 for ANA." The wings for this aircraft has been moved into position and should be soon followed by the three fuselage sections according to Jon.

Jon's Article

However, not all the news from Paris was positive for the 787. Qatar Airways is upset over the delays and Boeing's treatment of them. He threatened to pull the 60 plane order for the 787 if Boeing doesn't start to address their concerns. My opinion...Akbar Al Baker, Qatar Airway's CEO has been more impartial to Airbus thus he would always see Boeing in a harsher light. I consider him a wind bag who has to say outrageous things in order for him to stay relevant but unfortunately for a Boeing, he is someone that they would have to take seriously if they want to preserve their order.

Flight's Qatar Airways 787 story

Boeing: ZA002 goes to the fuel dock

Photos Courtesy of Boeing

Here's Boeing's press release on the 2nd Dreamliner going to the flightline:

News Release Issued: June 15, 2009 1:28 PM EDT
Second Boeing 787 Dreamliner Moves to Flight Line
EVERETT, Wash., June 15 /PRNewswire-FirstCall/ -- The second Boeing (NYSE: BA) 787 Dreamliner has moved to the flight line to begin fuel testing. This is the second of six 787s being used in the all-new airplane's flight-test program.
"Momentum continues to build with each milestone achieved," said Scott Fancher, vice president and general manager of the 787 Dreamliner program.
Each of the six flight-test airplanes will be used for a specific set of tests during the flight-test program. This airplane, designated ZA002, will focus on systems performance. Like its predecessor, ZA001, this airplane has successfully completed a rigorous series of tests while still in the factory. Fuel testing began immediately upon the airplane entering the fuel dock.
ZA002 features the livery of the Dreamliner's launch customer, ANA (All Nippon Airways) of Japan.
"ANA will be the first to fly the 787 Dreamliner in commercial service," Fancher noted. "We are honored to fly in ANA livery throughout the flight-test program as a tribute to our partnership in bringing this all-new airplane to market."
The 787 Dreamliner has 865 orders from 56 airlines.
Contact:
Mary Hanson
787 Dreamliner Communications
+1-206-898-4749
mary.hanson@boeing.com
SOURCE: Boeing

787 Update from Paris (and beyond)

UPDATE: ZA002 (N787EX) is out on at the Boeing fuel dock. Matt Cawby posted a photograph this morning showing the aircraft finally outside and ready to conduct fueling tests. First flight of ZA002 should take place by July 21st. Matt Cawby's Photo.

Well Boeing gave some more information into when the Dreamliner will finally leave the ground through it was hardly earth shattering news. First the first flight was not going to be event driven (ie not fly during the air show) but rather fly when it's ready to fly. This has been Boeing's mantra since August 2007.

Secondly, Scott Carson did say that it'll fly on June 30th which is the end of the 2nd quarter. Again not earth shattering news from Boeing. Jon Ostrower did post that it is possible that the schedule can be bought forward from June 30th, he cited program sources.

Now according to Jon's post (also from program sources), the way things are laid out over the next two weeks are as follow:

Now until through this weekend: preps for final gauntlet testing
Early next week: final gauntlet testing (about 2 days in length)
Middle of next week to the end of the week (June 25 or 26th): Inspections of 787 prior to start of taxi tests
Late next week through the weekend of June 27th-28th): taxi tests (787 moves under it's own power)
June 3oth: In the air

Now this is a zero margin schedule and as Jon said, it could move to the left depending on how further testing goes.

Jon also reported that Boeing and the partners in the supply chain agreed that all travelled work would be eliminated by airplane 14 which should be in final assembly by the end of this year. Alenia North America chief Giuseppe Giordo also said in Paris that it still takes Global Aeronautica about 300 days to finish the main fuselage section of the 787 but they are working on reducing that number. This probably accounts for all the sections flowing into the GA assembly sight in Charleston.
Guy Norris also put out an update on the 787 this morning. The first flight fuel verification testing that was supposed to take place today was actually completed on Sunday thus allowing for Boeing to proceed to the testing of the flight control system today (June 15th) with a focus on the tail and full deflection testing of the horizontal stabilizers (tail feathers). Guy also said that a few tests were completed on ZA002 in advance of it being rolled out of the hanger and to the fuel dock. According to my information, that was to have happened last night but I have not received verification of that yet.

Jon's 787 Update from Paris
Guy's 28th 787 Update

Paris 2009: Boeing to offer KC-777 (& KC-767), possible 777 revamp w/ 787-10 being looked at

Some musing coming out of Paris today.

First of all, and not entirely unexpected, Boeing will be offering up both the 767 and the 777 (presumably the 777F) for the USAF tanker competition against the EADS KC-330 tanker. Thus the tanker saga which has been years in the making continues to get interesting. It'll get it's own Lifetime TV movie by the time it's all done.

Next, Boeing's Commercial Airplanes Chief, Scott Carson, commented on the 777 future and said that Boeing might look at re-winging the popular twin in order to get more range in order to remain competitive with the A350 (specifically the A350-900 and A350-1000). Now it all comes to costs of redesigning the wing vs an all new design to supplant the 777 and remain competitive with the A350. Carson also did not rule out a larger 787 (the 787-10) which would seat about 310 people in a three class configuration. This aircraft would compete with the A350-900 while a re-winged 777-300ER would compete against the A350-1000. Before any of this can happen though, Boeing has to get the 787-8 into the air and into flight testing which will be the subject of another post.

Matt Cawby: ZA002 to the fuel dock late Sunday night

Matt Cawby has said that Dreamliner 2 (ZA002) should be at the fuel dock late Sunday night. It is also possible that the main fuselage section for ZA100 is being flown into Everett tonight as well as the LCF is on it's way to Everett from Charleston.

All this and the progress of ZA001 before the start of the Paris Air Show would give Boeing a lot to talk about during the press briefings on Monday and Tuesday.

Guy Norris: ZA001 starts final gauntlet on June 15th

Guy Norris posted today that ZA001 will start final gauntlet testing this Monday, June 15th. It'll start with a first flight fuel systems verification test. Additionally this weekend ZA001 is under going flight deck avionics testing as well as the stall warning systems test and tests of the Trent 1000 interface with the electronic engine control system.

Guy's 27th 787 update

Matt Cawby: ZA001 being prepared for taxi tests

Matt Cawby, an Everett -area photographer got a picture of Boeing technicians installing the static pressue cone on the tail of the aircraft. This is an indication that taxi tests are very close! However I still do not have an indication of when taxi tests would start.

Matt Cawby's photograph

787 First Flight Now Targeted for June 24

UPDATE (6/12/2009): Jon Ostrower wrote an article that appeared on Flight International's web site where he says that ZA001's first flight is days away. Could it be that it's 12 days away from today? Stay tuned!
787 flight is imminent by Jon Ostrower

Sources have told me that first flight for 787 is being targeted for June 24th. I am trying to confirm. This is all contingent upon Boeing finishing up all needed ground testing and no unexpected problems crop up as a result.

Please remember that this date is a moving target and not set in stone.

787 roundup - June 9, 2009

Lots of stuff today but nothing earth shattering. First Guy Norris of Aviation Week reported that Boeing is now analyzing data from the recently completed intermediate gauntlet tests on ZA001 and once the data has been reviewed a plan of action for the final gauntlet will probably be formulated and executed. ZA001 did have one post gauntlet test engine run on June 8th which should clear it for final gauntlet testing which Guy feels should start later this week.

Randy Tinseth give Boeing's perspective on the 787s intermediate gauntlet testing in his blog. What's very interesting is that when the test crew is buttoned up inside the 787 doing the gauntlet tests they're served meals and have full use of the airplanes' lavatories!

Lastly, Boeing released three videos of the gauntlet testing which are very fascinating to watch and give an idea of what the flight test team is doing to prepare for first flight.

Guy's 26th 787 Update Report
Randy's Journal - Learning to Fly



Getting to Gauntlet

Video Courtesy of Boeing

Going Through Gauntlet

Video Courtesy of Boeing

Men and Women of Gauntlet

Video Courtesy of Boeing

Flightblogger: 787 Intermediate Gauntlet Test Completed

Flightblogger says that Boeing confirmed the successful completion of the intermediate gauntlet tests. Boeing is pretty much set up for the start of final gauntlet testing after the intermediate was completed on Sunday afternoon (June 7th).

Jon also reported that ZA002 completed tests of its navigation system. ZA002 could be on the fuel dock as early as Tuesday for its fueling tests and calibration as well as spooling up its APU for the first time.

Flightblogger: Intermediate gauntlet complete

Flightblogger: Realizing the 787 Dream

Flightblogger wrote an expansive review of the 787 issues and progress covering a period from the Farnborough Air Show to today and looking ahead at what's in store for the 787 program in terms of production and flight testing. It's an incredibly great article which goes into great detail especially for what lies ahead in the program.

Realising the 787 dream

Guy Norris: Intermeidate Gauntlet Test on ZA001 completed!!

Guy Norris reported this afternoon that Boeing has completed intermediate gauntlet testing on the first 787 today. The results of the intermediate gauntlet testing apparently were better than expected thus eliminating the ened for further blocks of gauntlet testing by Boeing.
The process now moves to a systems test monitoring evaluation which Guy says should pave the way for the start on final gauntlet testing.

Guy's 25th 787 Update.

Guy Norris: Boeing into final aspects of intermediate gauntlet tests

Guy Norris is reporting that intermediate gauntlet testing is entering its final stages with blocks 17 and 18 completed last night and blocks 19 through 21 to be performed today into the night tonight. Blocks 19 and 20 specifically are geared to run through tests that would be performed during first flight. These blocks relate to refining the flight control software during the first flight.

ZA002 will be testing part of the navigation system called the earth reference system (ERS). Hopefully this airplane should be towed out to the fuel dock to go through fueling tests. I believe that ZA002 is still slated to fly about 3 weeks after ZA001. This could put ZA002's first flight around the first week of July.

ZA003 flight crew is undertaking more simulation training in the ITV, specifically on handling smoky situations arising from the forward and aft cargo bulk holds.

Guy's 787 Update #24

Boeing Videos of the 787

Video Courtesy of Boeing

Video Courtesy of Boeing

ZA001 intermediate gauntlet testing entering the final stages

Both Flightblogger and Guy Norris report that ZA001 is entering the final stages of it's intermediate gauntlet testing with no apparent issues thus far. The stage seems to be setting for the final gauntlet followed by taxi tests.

Both Guy and Jon are reporting that Boeing is on block 14 and block 15 which covers environmental controls and more common core systems (CCS) testing today. On Thursday will see electrical systems tests, as well as pilot conditions tests and a final CCS test which will go into early Friday morning.

ZA002 is progressing through it's factory gauntlet and should be out by the fuel dock to go through the similar fueling tests that ZA001.

Additionally, Jon is reporting that the main fuselage section for ZA100, the first production aircraft for ANA, is being kept at Charleston, SC to finish off work and to ensure that there isn't any travelled work.

Flightblogger June 3rd Report
Guy's 23rd 787 Report

Here's a video from Liz Matzelle of Dreamliner 1 undergoing gauntlet tests on the Boeing ramp:

Simulated Dreamliner Test Flights from Liz Matzelle on Vimeo.

Flightblogger: Spirit to ship 787 sections at about a 2/month rate

Flightblogger sent out a few Tweets this afternoon about Spirit's prodcution of the 787 forward fuselage sections. Spirit will deliver 10 - 12 787 section 41s this year (2009) to Boeing (they've delivered 3 thus far this year).

They say that they are capable of making 7/month right now but they'll be doing 2/month for the 2nd half of 2009 and for 2010 or until Boeing give them a go for increasing beyond the 2/month rate. The last section they'll deliver this year will be for LN17.

So that automatically says that Boeing expects to produce 2 787s per month until the end of 2010 it seems though if they could up that rate before the end of 2010 I'm sure they'll do that. To me that doesn't sound very promising for their earnings in 2010.

Spirit does plan to up production to 7/month later on but didn't give a time frame as to when that will happen. Boeing has said that it expects to hit 10/month production rate sometime in 2012.

Jon posted an update to his blog:

Jon's Spirit Update

Guy Norris: Intermediate Gauntlet Testing Continues with further block tests

Guy posted that Boeing is still continuing with gauntlet testing and are now up to test blocks 8 through 11 with block 11 expected to be completed by late Tuesday. Boeing does expect to complete intermediate gauntlet by this Wednesday. No word on when final gauntlet will start.

I do expect that ZA002 will go through gauntlet testing as will ZA005 which is the first GEnx airplane. I'm not sure about the other test airplanes but they will eventually go through some period of pre-flight testing before their first flights. I'm still maintaining my prediction for first flight after the Paris Air Show and specifically around June 19th (note: I erroneously put the 9th, duhhh).

Boeing will make it June 18th just to spite me. Just kidding Boeing!

Guy's 22nd 787 post.

Flightblogger: Boeing confirms 787 intermediate gauntlet tests

Flightblogger confirmed that ZA001 has started intermediate gauntlet testing which should be completed by this Friday at the latest. Jon also said that high powered engine runs were conducted on Friday (May 29th) prior to the start of gauntlet testing.
Boeing also confirmed the start of the tests on Randy Tinseth's blog that was posted last night. In his blog, Randy says that they won't expect to put out any more progress reports over the next few days as they're busy getting and analyzing data during this testing. Randy also linked to a great video of the first engine run on ZA001.

Flightblogger posting confirming start of intermediate gauntlet testing.

Randy's Blog: The Gauntlet Begins