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Published: Friday, August 14, 2009

787 parts supplier stops work

Boeing halted work at Italian company in June after fuselage flaws are found

The Boeing Co. knew it had multiple problems with its delayed 787 Dreamliner on the day it scrapped the jet's first flight in June.

Boeing's 787 partner Alenia Aeronautica was ordered to stop work on the fuselage sections it supplies to Boeing due to wrinkling of the section's composite. The stop-work order notification was sent to the Italian supplier on the same day that Boeing went public with its fifth major delay.

The problem with Alenia's section was first reported late Thursday on Flight Global's FlightBlogger site, which obtained a copy of the stop-work order. Boeing spokeswoman Lori Gunter confirmed the problem in an interview.

Gunter downplayed the significance of the supplier issue, describing it as a common development in a new airplane. Gunter said that Boeing officials didn't disclose the problem previously because it “didn't have any impact on schedule or cost.”

Boeing does not believe the first four 787 flight test planes are affected, Gunter said. The company is still evaluating flight test planes five and six, which also are believed to be unaffected. However, airplanes 7 through 29 will require a “simple patch” to solve the problem, she said.

After assuring the public at the Paris Air Show that its 787 would fly by the end of June, Boeing officials acknowledged on June 23 that the mostly composite aircraft's first flight would be postponed indefinitely, citing the need to reinforce the area where the jet's wings join its fuselage. But the company officials didn't mention the problem with Alenia's pieces.

At the time, Boeing called the problem “manageable” and “limited.” But more than seven weeks later, Boeing still hasn't disclosed a new schedule for the delayed Dreamliner.

Boeing is relying on multiple global partners, including its Japanese wing supplier Mitsubishi Heavy Industries, for major 787 structures. Major structures go through final assembly in Everett.

The company recently bought out Vought Aircraft Industries, a major Dreamliner supplier in South Carolina. The purchase sparked concern here that Boeing might set up a second production line there.

Despite running nearly two years behind schedule, Boeing's 787 has won more than 850 orders.

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787

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