Boeing 787 design and manufacture safe, FAA says

WASHINGTON — U.S. regulators and Boeing didn’t exercise enough quality control over subcontractors during the 787 Dreamliner’s development, according to a review prompted by battery failures that led to the longest grounding of a commercial airplane since the 1950s.

The review found that the Dreamliner is safe, meets design standards and is about as reliable as other Boeing jetliners were after being introduced. The Federal Aviation Administration issued seven recommendations, four for Boeing and three for itself, to improve the way new-aircraft design and manufacturing is overseen.

“The review team identified some problems with the manufacturing process and the way we oversee it, and we are moving quickly to address those problems,” FAA Administrator Michael Huerta said in a statement.

The FAA’s review of the 787’s certification and manufacturing, announced in January 2013, is separate from an ongoing probe by the National Transportation Safety Board into what caused the battery incidents.

“We welcomed the opportunity presented by this joint review,” Ray Conner, Boeing commercial airplanes president and chief executive officer, said in a statement. “The findings validate our confidence in both the design of the airplane and the disciplined process used to identify and correct in-service issues as they arise.”

The two cases in which 787 batteries overheated and emitted fumes in the U.S. and Japan were another blemish on a more-efficient plane that was beset with manufacturing delays and production issues. Those pushed its introduction more than three years behind schedule.

The 787 fell behind in part because Boeing turned over more authority to suppliers than during development of previous models. The arrangement, intended to cut costs and reduce Boeing risk, caused a series of delays starting in October 2007.

The first battery incident occurred Jan. 7, 2013, in Boston aboard a Japan Airlines plane that had arrived from Tokyo. It emitted fumes and gave off high heat, as if it was on fire, according to the NTSB.

While no one was hurt and the plane didn’t suffer significant damage, the NTSB opened an investigation because the aircraft was new and had just recently entered service.

Two days later, an All Nippon Airways 787 made an emergency landing at Takamatsu Airport in southern Japan after another lithium-ion battery overheated and fumes entered the cabin.

Both Japanese carriers halted flight of 787s, and the FAA followed on Jan. 17 with its order grounding the plane, the first such action in 34 years. At the time, there were 49 Dreamliners in service.

One hundreds days after the grounding, on April 19, the FAA announced it had approved a set of more-rigorous battery standards and allowed the plane to resume commercial operations.

The FAA directive required multiple additional protections for the battery system. Each of the individual eight cells was to be placed in a protective sleeve. The cells were enclosed in a steel case to prevent heat and fire from damaging a plane. A vent was devised so that any fumes would go outside the plane and not enter the cabin.

GS Yuasa Corp., based in Kyoto, Japan, makes the batteries, which are part of an electrical system built by France’s Thales. United Technologies Corp.’s Aerospace Systems unit supplies the system, which uses 1.45 megawatts of electricity, enough to power 400 homes.

In its statement Wednesday, Boeing said it has instituted changes in the new-airplane development process, particularly with regard to outsourcing.

“The review team outlined four recommended improvements for Boeing,” the company said. “Three of the recommendations focus on improving the flow of information, standards and expectations between the company and its suppliers. Boeing has already taken significant steps to implement these recommendations.

“The fourth recommendation encourages Boeing to continue implementing and maturing the gated processes for development programs,” Boeing said.

“‘Gated process’ refers to the disciplined criteria followed as a new airplane model is developed. This ensures a sufficient level of maturity is gained before a program proceeds to key milestones such as design completion, production start and entry into service,” the company said.

Meanwhile, the review recommended that the FAA revise how it oversees new-airplane development programs “to recognize new aircraft manufacturing business models” and implement better production-approval procedures “to more fully address complex, large-scale manufacturers with extended supply chains.”

Boeing had delivered 122 Dreamliners through last month, according to the company’s website, most from the big factory in Everett but also from North Charleston, S.C. Airlines have ordered 1,031 Dreamliners in all.

While the manufacturer boosted monthly production of the 787 to 10 from seven at the end of 2013, it has struggled to match deliveries with that schedule. The company had handed over only eight planes to airlines this year through February.

Boeing is also contending with the potential for hairline cracks in wings on about 40 Dreamliners after supplier Mitsubishi Heavy Industries changed a manufacturing process, the company announced March 8. None of those 40 planes had been delivered to airlines.

After the 2013 battery incidents and grounding, Boeing shares fell, from a close of $77.69 Jan. 4 to $73.65 Jan. 29, a 5.2 percent drop. As the investigation progressed and a fix was instituted, the shares climbed.

Shares have risen about 30 percent since the FAA announced it approved Boeing’s fix for the 787, last April 19.

Dreamliners are the first commercial jets built chiefly of spun composite fibers instead of the traditional aluminum. The composite wing is distinctive for its 190-foot span and raked tips and, according to Boeing’s website, is about 20 percent lighter because of the new materials.

Herald staff contributed.

Talk to us

> Give us your news tips.

> Send us a letter to the editor.

> More Herald contact information.

More in Business

A closing sign hangs above the entrance of the Big Lots at Evergreen and Madison on Monday, July 22, 2024, in Everett, Washington. (Ryan Berry / The Herald)
Big Lots announces it will shutter Everett and Lynnwood stores

The Marysville store will remain open for now. The retailer reported declining sales in the first quarter of the year.

George Montemor poses for a photo in front of his office in Lynnwood, Washington on Tuesday, July 30, 2024.  (Annie Barker / The Herald)
Despite high mortgage rates, Snohomish County home market still competitive

Snohomish County homes priced from $550K to $850K are pulling in multiple offers and selling quickly.

Henry M. Jackson High School’s robotic team, Jack in the Bot, shake hands at the 2024 Indiana Robotics Invitational.(Henry M. Jackson High School)
Mill Creek robotics team — Jack in the Bot — wins big

Henry M. Jackson High School students took first place at the Indiana Robotic Invitational for the second year in a row.

The computer science and robotics and artificial intelligence department faculty includes (left to right) faculty department head Allison Obourn; Dean Carey Schroyer; Ishaani Priyadarshini; ROBAI department head Sirine Maalej and Charlene Lugli. PHOTO: Arutyun Sargsyan / Edmonds College.
Edmonds College to offer 2 new four-year degree programs

The college is accepting applications for bachelor programs in computer science as well as robotics and artificial intelligence.

FILE — Boeing 737 MAX8 airplanes on the assembly line at the Boeing plant in Renton, Wash., on March 27, 2019. Boeing said on Wednesday, Feb. 21, 2024, that it was shaking up the leadership in its commercial airplanes unit after a harrowing incident last month during which a piece fell off a 737 Max 9 jet in flight. (Ruth Fremson/The New York Times)
Federal judge rejects Boeing’s guilty plea related to 737 Max crashes

The plea agreement included a fine of up to $487 million and three years of probation.

Neetha Hsu practices a command with Marley, left, and Andie Holsten practices with Oshie, right, during a puppy training class at The Everett Zoom Room in Everett, Washington on Wednesday, July 3, 2024. (Annie Barker / The Herald)
Tricks of the trade: New Everett dog training gym is a people-pleaser

Everett Zoom Room offers training for puppies, dogs and their owners: “We don’t train dogs, we train the people who love them.”

Andy Bronson/ The Herald 

Everett mayor Ray Stephenson looks over the city on Tuesday, Jan. 5, 2015 in Everett, Wa. Stephanson sees  Utah’s “housing first” model – dealing with homelessness first before tackling related issues – is one Everett and Snohomish County should adopt.

Local:issuesStephanson

Shot on: 1/5/16
Economic Alliance taps former Everett mayor as CEO

Ray Stephanson will serve as the interim leader of the Snohomish County group.

Molbak's Garden + Home in Woodinville, Washington will close on Jan. 28. (Photo courtesy of Molbak's)
After tumultuous year, Molbak’s is being demolished in Woodinville

The beloved garden store closed in January. And a fundraising initiative to revitalize the space fell short.

Everett Mayor Cassie Franklin, Advanced Manufacturing Skills Center executive director Larry Cluphf, Boeing Director of manufacturing and safety Cameron Myers, Edmonds College President Amit Singh, U.S. Rep. Rick Larsen, and Snohomish County Executive Dave Somers participate in a ribbon-cutting ceremony on Tuesday, July 2 celebrating the opening of a new fuselage training lab at Paine Field. Credit: Arutyun Sargsyan / Edmonds College
‘Magic happens’: Paine Field aerospace center dedicates new hands-on lab

Last month, Edmonds College officials cut the ribbon on a new training lab — a section of a 12-ton Boeing 767 tanker.

Gov. Jay Inslee presents CEO Fredrik Hellstrom with the Swedish flag during a grand opening ceremony for Sweden-based Echandia on Tuesday, July 30, 2024, in Marysville, Washington. (Ryan Berry / The Herald)
Swedish battery maker opens first U.S. facility in Marysville

Echandia’s marine battery systems power everything from tug boats to passenger and car ferries.

Helion Energy CEO and co-founder David Kirtley talks to Governor Jay Inslee about Trenta, Helion’s 6th fusion prototype, during a tour of their facility on Tuesday, July 9, 2024 in Everett, Washington. (Olivia Vanni / The Herald)
State grants Everett-based Helion a fusion energy license

The permit allows Helion to use radioactive materials to operate the company’s fusion generator.

People walk past the new J.sweets storefront in Alderwood Mall on Thursday, July 25, 2024, in Lynnwood, Washington. (Olivia Vanni / The Herald)
New Japanese-style sweets shop to open in Lynnwood

J. Sweets, offering traditional Japanese and western style treats opens, could open by early August at the Alderwood mall.

Support local journalism

If you value local news, make a gift now to support the trusted journalism you get in The Daily Herald. Donations processed in this system are not tax deductible.