DRAFT: This module has unpublished changes.
DRAFT: This module has unpublished changes.

Boeing 787 Dreamliner SCM Problems

Facts

  • Improper R & D required the company to rebuild a panel of the plane late in the production schedule. (Cnet)
  • The schedule had a reasonable amount of risk to handle such a situation, but it would be inaccurate and disingenuous to not acknowledge the potential. (Cnet)
  • In December 2006, the first six 787s were overweight. As part of this weight reduction process, Boeing redesigned some parts and made more use of lighter titanium. (Wikipedia)
  • At the end of August 2007, Boeing planned its first flight, but was delayed because the aircraft’s major systems had not been installed at that time. (Wikipedia)
  • On September 5, 2007, a three-month delay was due to a shortage of fasteners as well as incomplete software. (Wikipedia)
  • On October 10, 2007, a 2nd three-month delay to the first flight and a six-month delay to first deliveries were announced. They were due to problems with the foreign and domestic supply chain, including an ongoing fastener shortage, the lack of documentation from overseas suppliers, and continuing delays with the flight guidance software. Less than a week later, Mike Bair, the 787 program manager was removed from his position. (Wikipedia)
  • On January 16, 2008, a 3rd three-month delay to the first flight due to “traveled work” was announced. (Wikipedia)
  • On March 28, 2008, in order to gain more control over the supply chain, Boeing planned to buy Vought Aircraft Industries’ interest in Global Aeronautica and its North Charleston, SC factory. (Wikipedia)
  • April 9, 2008, a 4th delay was announced.  This shifted the first flight to the 4th quarter of 2008 and initial deliveries to the 3rd  quarter of 2009. (Wikipedia)
  • Ongoing challenges with out-of-sequence production work, including parts shortages, and remaining software and systems integration activities."57-day machinists strike, which ended on November 1, 2008. (Wikipedia)
  • On November 4, 2008, a 5th delay was due to incorrect fastener installation and the Boeing machinists strike. (Wikipedia)
  • On December 11, 2008, the first flight got delayed until the 2nd quarter of 2009, after assessing the 787 program schedule with its suppliers. (Wikipedia)
  • On June 23, 2009, Boeing announced that the first flight was postponed, "due to a need to reinforce an area within the side-of-body section of the aircraft.” (Wikipedia)
  • On December 15, 2009, the Dreamliner's maiden flight with the first 787-8. Boeing’s schedule called for an 8.5 month flight test campaign. (Wikipedia)
  • On August 27, 2010 the Rolls- Royce Trent engine failed its test. (NY Times)
  • On November 5, 2010, it was reported that some early 787 deliveries may be delayed, in one case some three months, to allow for rework to address issues found during flight testing. (Wikipedia)
  • On November 9, 2010, Boeing 787, ZA002 made an emergency landing after smoke and flames were detected in the main cabin during a test flight over Texas. The electrical fire caused some systems to fail before landing. (Wikipedia)
  • On December 23, 2010, after electrical system and software changes, the 787 resumed company flight testing. (Wikipedia)
  • On January 2011, the first 787 delivery was rescheduled to the 3rd quarter of 2011 due to software and electrical updates following the in-flight fire.(Wikipedia)
  • On August 2011, Boeing completed certification testing for Rolls-Royce powered 787-8s on August 13, 2011. The FAA and European Aviation Safety Agency certified the 787 on August 26, 2011 at a ceremony in Everett, Washington. (Wikipedia)
  • On September 25, 2011, the first 787 was officially delivered to All Nippon Airways at Boeing's facilities in Everett, Washington. (Wikipedia)

Summary

  • Boeing was challenged by start-up issues in the factory and in the extended global supply-chain.  Parts were sourced literally all over the world and too high of a quantity of suppliers were used.  Since Boeing were outsourcing globally it appears that they did not factor in the risk management of their supply chain.
  • Boeing should find a right balance between outsourcing and the highly centralized production systems. Boeing was outsourcing a great amount of 787 Dreamliner’s production, causing the company lost its control over the program.
  • Boeing did not take into consideration how long the plane would take to be built while factoring in complications and generous lead times for parts.  This rush mentality caused many problems as people worked around the clock to meet deadlines, but sometimes compromising the quality of what was being made.
DRAFT: This module has unpublished changes.