Boeing: 787 first flight 'expected' by year end, first delivery in 2010 fourth quarter

Boeing said yesterday that 787 first flight "is expected by the end of 2009" with first delivery to launch customer ANA pushed back to the 2010 fourth quarter, a schedule that allows for a longer flight test program than previously planned to provide "some cushion. . .to account for unknowns."

Until the latest setback was disclosed in June, (ATWOnline, June 24) the manufacturer had expected to deliver the 787 to ANA in the 2010 first quarter. In a statement, the airline said, "The length of this further delay is a source of great dismay, not to say frustration."

Boeing added that it will not reach a production rate of 10 Dreamliners per month--which will necessitate a second production line--until "late 2013." Delivery of the larger, longer-range 787-9 will not occur until the 2013 fourth quarter.

It also revealed that it will take a $2.5 billion noncash charge in the current quarter owing to its determination that the first three of six flight test aircraft no longer are commercially marketable because of "extensive modification work" and will not be placed with customers, becoming a research and development expense rather than inventory.

Chairman, President and CEO Jim McNerney told analysts and reporters that Boeing has developed the upper wing join area fix to be made on both sides of the aircraft to address the structural weakness identified in June (ATWOnline, Aug. 10).

Discussing the fix, VP and GM-Airplane Programs Pat Shanahan said "four to five new fittings will be installed on each stringer" in the wing join area on both sides of the 787's body to reinforce the structure against stress. While he described the modification as relatively simple, he said the installations on completed aircraft are "paced by limited access" to the area in question and a limitation on the number of mechanics who can be in the wing box at a given time. The fix will be made on the static test aircraft, which will have to pass the test that caused the excessive stress before first flight can occur, he noted.

Boeing did not release a delivery schedule beyond the first delivery in next year's fourth quarter. Commercial Airplanes President and CEO Scott Carson said the company is in discussions with the customers for the more than 800 787s on order, assessing the financial situation of each and their "appetite" for taking Dreamliners at a particular time.

Shanahan said the manufacturer has made no changes to the aggressive 8.5-9-month flight test program that it originally planned even though it now will have 11-12 months to conduct the program and gain certification (ATWOnline, April 30). "Our basic approach is the same," he said. "Think of [the added time] as buffering the customer."