Mon, May 28, 2012, 6:58 AM EDT - U.S. Markets closed for Memorial Day

Boeing says it's frustrated with Dreamliner glitch

Boeing says it's frustrated with latest Dreamliner glitch, production goals unchanged

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SINGAPORE (AP) -- Boeing Co., the world's second-largest plane maker, is frustrated with the latest 787 Dreamliner production glitch, but it shouldn't delay output goals, a top executive said Sunday.

Boeing has fixed a shimming problem discovered earlier this month on some 787 fuselages and plans to inspect other planes for the error, Boeing vice president of 787 development Mark Jenks said. Shims are used to close tiny gaps in joints.

"It's a pretty straightforward issue," Jenks told reporters in Singapore. "It shouldn't have any significant impact on our production ramp-up."

Boeing still plans to boost production from a current two to three 787s per month to 10 of the planes per month by the end of next year, Jenks said. Boeing delivered its first Dreamliners last year to All Nippon Airways after a parts shortage, a labor strike and a fire on a test flight triggered several delays and pushed back delivery by three years.

"Clearly it's frustrating, and we'd rather it not happen," Jenks said. "We've really moved from some things that early on hit us that really were sort of unusual with the new technology, now to these kinds of things which really aren't that different from the problems we always have to face when we ramp up production."

The Dreamliner is the world's first commercial plane made mostly of lighter-weight composite materials. Boeing says the plane cuts fuel consumption by 20 percent and lowers operating costs by 30 percent.

The planes also feature a high ceiling, bigger windows that can darken and softer lighting.

The first Dreamliner version, the 787-8, carries between 210 and 250 passengers. Boeing plans to deliver the 787-9, which is longer and carries between 250 and 290 passengers, by early 2014.

Jenks said Boeing is currently studying a possible 787-10, which would be bigger than the 787-9.

Boeing has received orders for 870 Dreamliners from 59 airlines and is showcasing the plane at this week's Singapore Airshow.

 

69 comments

  • Met Fan Lou  •  Fort Worth, Texas  •  3 months ago
    Sir here's your boarding pass and an extra shim just in case. Enjoy your flight.
  • Torn  •  Wichita, Kansas  •  3 months ago
    Well if you would make it in house, you could cure a lot of these problems, I know Boeing claims all it's "partners" make it easier to sell aircraft in their countries, but guess what nobody wants to buy an aircraft with all these problems. Think a little bit about the THOUSANDS of jobs outsourced to other countries. If those jobs were here in this country, people might be able to afford to fly more thus selling more planes. What goes around comes around.
    • Nuclear Mullah 3 months ago
      Incorrect. You have to outsource to get our trading partners to buy. 100% US plane would not sell overseas.
    • Pi 3 months ago
      FYI, this particular component in question is fabricated by Boeing South Carolina, start to finish. So much for thinking that making it in house cures problems.
    • Jared 3 months ago
      I find it comical that you blame the CEO and executives for out sourcing.. It's really this simply the USA made production costs far greater then that in other Nations. The other Nations produce the same quality product at a cheaper price. If you can't find a way to compete with their price or beat their quality you go bankrupt. Even with better quality lower price almost always wins out. When you factor in labor, regulation, litigation, taxes and so on production costs in the USA are 10-15x higher.

      These companies want to compete in a GLOBAL Economy.. That WE created.
  • NikolaZ  •  3 months ago
    you think your frustrated, ask airbus about the hair line cracks!
    • Les O 3 months ago
      And vertical stabs that fall off! Plus massive govt subsidies!
  • Rob  •  Algonquin, Illinois  •  3 months ago
    Maybe if they'd hire people who are the most qualified for the job instead of the best "personality fit" this wouldn't be an issue.
  • GARY S  •  Charleston, South Carolina  •  3 months ago
    Nothing that can't be fixed with a little duct tape.
  • harry  •  Tacoma, Washington  •  3 months ago
    Boeing could have prevented this shimming process had they built the dreamliner in the US of A rather than having parts come from all over the planet. So to Boeing I say you're a shimmer and should repent. Move the jobs back to the US of A and build a great airplane.
    • Les O 3 months ago
      They shipped a lot of design overseas too. The Japanese now design the wings, that was Boeing's major advantage now they are permanently screwed!
    • Rich 3 months ago
      Maybe they need some Union concessions? Look what happened to GM.
    • harry 3 months ago
      Wonder how long it will be before the whole plane is built in China?
  • Yahoo user  •  3 months ago
    So what exactly is the problem here and how are they fixing it? More details please.
    • Pi 3 months ago
      More details? Here...

      "Boeing has found that incorrect shimming was performed on support structure on the aft fuselage on certain airplanes in our facility in Everett, [Washington]. Boeing declined to say how many 787s have this issue, though sources indicated that there are "significantly more" than the three initially identified in the factory.

      Programme sources say the stiffeners, or longerons that run along the length of the aircraft, are delaminating around the rear opening of the Section 48 section above and below the cutout known as the "bird's mouth" that holds the Alenia Aeronautica-built horizontal stabiliser.

      Boeing said the issue is a "straightforward repair" and poses no "short-term safety concern" and the airframer said its inspections have revealed "delamination in some instances." Boeing is currently conducting inspections on the already built 787s and those waiting to be assembled, at least 50 airframes, in Everett and its North Charleston, South Carolina facilities.

      "We have this condition well-defined and we are making progress on the repair plan," said Boeing and declined to say if the inspections were slowing preparations for delivering additional 787s.

      The issue, identified around 24 January was traced to assembly of the aft fuselage by Boeing South Carolina, Formerly Vought Aircraft Industries, where Sections 47 and 48 are fabricated, assembled and stuffed with systems before being delivered to final assembly lines in North Charleston or Everett.

      When the longerons are installed on the wound carbon fibre barrel, frames and longerons are secured to the skin of the structure to give it strength. When natural variations in the fit of parts exists, aerospace mechanics will install shims, or spacers, which compensate for variations and wedge into structure to create a tighter fit.

      Without the shims, damage can be sustained to the composite when fasteners are installed by pulling the structure together, damaging the layers of carbon fibre.

      Over the long-term composite delamination can decrease the fatigue life of the aircraft's structure.

      Boeing said it has "already taken appropriate steps to address this issue" in South Carolina, declining to elaborate on what steps it has taken."

      Enough details?
  • johnlwheeler2  •  Woodford, Virginia  •  3 months ago
    Glitch = too many sub-contractors in US and around the world Japan, Italy, Korea, Britain Australia, Canada and Russia. Even though some are financial partners bring all the manufacturing back to the USA, after all you do get a lot of TAX PAYER'S MONEY from military contracts
  • be carefull  •  3 months ago
    that is what you get when you build a plane from parts from all over the world.You can't control quality from your office
  • Peter Wilson  •  3 months ago
    Speaking of glitches, why does yahoo allow me to post here, but not the political articles?
    Am I being censored, or is my computer improperly shimmed?
    • JORGE L 3 months ago
      Lambada. You are correct we are been censored, is not your computer is state control media.
    • GARY S 3 months ago
      Yahoo does not allow the mentally challenged to post.
    • Tom 3 months ago
      Excellent question !
  • ChristopherB  •  3 months ago
    Newark area anyway says please keep em safe !
  • ChristopherB  •  3 months ago
    Shimm why shimm y (just eat your wheaties and don't try the coco pops ) who can you trust for the dawn of a safer day without scrimping on products while paychecks for hard workers who do as they're told can't make ends meet ? Yet unions make some of the best money around ....
  • William  •  3 months ago
    Anyone remember the old Electras whose wings would fall off in flight? Duct tape didn't work on them either.
  • W  •  3 months ago
    I fly albatross myself. No shims to worry about. I hold a small fish out in front.Steering by pulling on the wings. Works fine as long as it is not raining.
  • AP  •  3 months ago
    Lot of problems with Boeing manufacturing is its long and far flung supply chain. The manufacturing process at 2-3 aircrafts a month is like handcrafted assembly. Today's aircraft manufacturing is nothing like what was done during WWII when some of the auto manufacturing assembly line concepts were adopted.
  • Tiger  •  3 months ago
    I do not see what the Union has to do with the problem.
  • gwaygoo  •  Phoenix, Arizona  •  3 months ago
    Pilots nowadays are basically just there to keep an eye on things while the plane flys itself.
  • Fillup  •  3 months ago
    I have a problem with todays management. It seems it manifests itself to the general public at Airbus and Boeing. They just have played politics with the aiirplane. In order to get an airplane order they have to give the country the airline comes from some of the manufacturing of the airplane. In the social media CEO's come and go and when they leave the screwed up mess behind they leave with millions of dollars in severance. I suggeest that when chief executive officers leave a company that they have screwed up that they be taken out and shot. Why should the average worker take it in the neck for them. Seriously management today is not as good as it was say 20 years ago. Tune in to CNBC, They just love those guys and gals.
  • Seneca  •  3 months ago
    I say duct tape!
    It works wonders!
  • Hugh  •  Farmington, Michigan  •  3 months ago
    Their dream is turning into a nightmare.
 
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