Boeing finds another 787 manufacturing problem

Boeing has discovered a manufacturing error causing delamination in the plastic-composite aft fuselage section of some 787 Dreamliners, according to a person with knowledge of the problem.
By Dominic Gates Seattle Times aerospace reporter

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Yet another reason outsourcing was a bad idea. Build it here and whatever errors that... (February 5, 2012, by charl317) MORE "You can start 1st with HORRIBLE Seattle-based program management when this whole... (February 5, 2012, by F16CrewChief) MORE aloha charlie The people you are referring to is McDonald Douglas. While at the... (February 5, 2012, by tomday09) MORE
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Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

Boeing has discovered a manufacturing error causing delamination in the plastic-composite aft fuselage section of some 787 Dreamliners, according to a person with knowledge of the problem. Boeing is inspecting all the airplanes already built to find the extent of the issue. In a brief statement Sunday, Boeing said, "We have the issue well defined and are making progress on the repair plan. There is no short-term safety concern." Boeing's statement didn't acknowledge the issue involves delamination. It said unspecified damage resulted from "incorrect shimming performed on support structure on the aft fuselage of some 787s." Mechanics install shims, or spacers, to fill small gaps that occur between parts that don't fit together exactly. An earlier problem arose in 2010 with faulty shimming by mechanics working for Alenia building the 787's horizontal tail in Italy. They had applied too much torque when tightening fasteners, and the consequent compression of the shims degraded the composite material. At that time, those manufacturing quality issues with the horizontal tails added months of delays to the jet program. Many airplanes had to have their tails extensively reworked. This time, the delamination is happening in a section of the aft fuselage near where the horizontal tail is joined. Boeing has completed assembly of about 50 Dreamliners to date, and has delivered five, to launch customer All Nippon Airways of Japan. The plane entered service in 2011 after more than three years of delays. Flightglobal, the website for Flight International magazine, reported Saturday that structural stiffening rods, which had been hardened together Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

with the fuselage skin in massive ovens, had partially separated from the skins. The Dreamliner's aft fuselage section is manufactured in Charleston, S.C., at the former Vought plant that Boeing took over in 2009. On Sunday, Boeing played down the problem, saying that "repairs, should they be needed, will be implemented in the most efficient manner possible." However, if the fuselage repairs are needed in a large number of planes, that could further slow the already slothlike pace of Dreamliner deliveries. According to the person with knowledge of the issue, any plane in which this fault has been discovered is not allowed to operate beyond "limit load," the term for the maximum load projected in normal service. However, the planes must be certified to sustain 1.5 times that load, a standard called "ultimate load," for certification and delivery. The person said discovery of the problem held back some flight tests needed to certify the version of the Dreamliner fitted with General Electric engines. The initial model with Rolls-Royce engines is already certified. Boeing did not provide detail beyond its short statement on the issue. It was left unclear whether the delamination has been found on any of the five Dreamliners already delivered and in passenger service for All Nippon Airways. Dominic Gates: 206-464-2963 or dgates@seattletimes.com

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

Boeing finds another 787 manufacturing problem

Boeing has discovered a manufacturing error causing delamination in the plastic-composite aft fuselage section of some 787 Dreamliners, according to a person with knowledge of the problem.
By Dominic Gates Seattle Times aerospace reporter

RELATED

Boeing's real-time stock price

MOST POPULAR COMMENTS

HIDE / SHOW COMMENTS

Yet another reason outsourcing was a bad idea. Build it here and whatever errors that... (February 5, 2012, by charl317) MORE "You can start 1st with HORRIBLE Seattle-based program management when this whole... (February 5, 2012, by F16CrewChief) MORE aloha charlie The people you are referring to is McDonald Douglas. While at the... (February 5, 2012, by tomday09) MORE
Read all 116 comments Post a comment

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

Boeing has discovered a manufacturing error causing delamination in the plastic-composite aft fuselage section of some 787 Dreamliners, according to a person with knowledge of the problem. Boeing is inspecting all the airplanes already built to find the extent of the issue. In a brief statement Sunday, Boeing said, "We have the issue well defined and are making progress on the repair plan. There is no short-term safety concern." Boeing's statement didn't acknowledge the issue involves delamination. It said unspecified damage resulted from "incorrect shimming performed on support structure on the aft fuselage of some 787s." Mechanics install shims, or spacers, to fill small gaps that occur between parts that don't fit together exactly. An earlier problem arose in 2010 with faulty shimming by mechanics working for Alenia building the 787's horizontal tail in Italy. They had applied too much torque when tightening fasteners, and the consequent compression of the shims degraded the composite material. At that time, those manufacturing quality issues with the horizontal tails added months of delays to the jet program. Many airplanes had to have their tails extensively reworked. This time, the delamination is happening in a section of the aft fuselage near where the horizontal tail is joined. Boeing has completed assembly of about 50 Dreamliners to date, and has delivered five, to launch customer All Nippon Airways of Japan. The plane entered service in 2011 after more than three years of delays. Flightglobal, the website for Flight International magazine, reported Saturday that structural stiffening rods, which had been hardened together Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

with the fuselage skin in massive ovens, had partially separated from the skins. The Dreamliner's aft fuselage section is manufactured in Charleston, S.C., at the former Vought plant that Boeing took over in 2009. On Sunday, Boeing played down the problem, saying that "repairs, should they be needed, will be implemented in the most efficient manner possible." However, if the fuselage repairs are needed in a large number of planes, that could further slow the already slothlike pace of Dreamliner deliveries. According to the person with knowledge of the issue, any plane in which this fault has been discovered is not allowed to operate beyond "limit load," the term for the maximum load projected in normal service. However, the planes must be certified to sustain 1.5 times that load, a standard called "ultimate load," for certification and delivery. The person said discovery of the problem held back some flight tests needed to certify the version of the Dreamliner fitted with General Electric engines. The initial model with Rolls-Royce engines is already certified. Boeing did not provide detail beyond its short statement on the issue. It was left unclear whether the delamination has been found on any of the five Dreamliners already delivered and in passenger service for All Nippon Airways. Dominic Gates: 206-464-2963 or dgates@seattletimes.com

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations. Requirements The Boeing Quality Management System Requirements for Suppliers document (D6-82479 - pdf file) contains the supplier management quality system requirements of The Boeing Company. Requirements are described in three appendixes and two addenda, the applicability of which shall be defined by contract. This document is an expression of the expectation by The Boeing Company of all of our suppliers today and in the future. Appendix A - AS9100C, Quality Management Systems Requirements for Aviation, Space and Defense Organizations
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This appendix describes the quality management system requirements for Boeing suppliers as contained in ISO 9001 as supplemented by 9100 which includes all IAQG sanctioned standards including but not limited to AS9100C, EN9100 and JISQ 9100. Appendix A represents the International aerospace quality standard for quality assurance in design, development, production, installation, and servicing.

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

Boeing Appendix A suppliers will be AS/EN/JISQ 9100*, "Quality Management Systems - Requirements for Aviation, Space and Defense Organizations" certified by an accredited Certification Body listed in the International Aerospace Quality Group's (IAQG) OASIS database. The Boeing Company has adopted the AS/EN/JISQ 9100* transition timeline as sanctioned by the International Aerospace Quality Group (IAQG). Transition will be in accordance with the schedule referenced on the OASIS database.http://www.iaqg.sae.org/servlets/index?PORTAL_C ODE=IAQG For Suppliers under contract for Maintenance, Repair or Overhaul (MRO), the Seller's AS/EN?JISQ9100* certification shall have an associated CB assessment report/package that contains evidence that Service process was assessed or will be AS/EN 9110**, "Quality Management Systems Requirements for Aviation Maintenance Organizations" certified by an accredited Certification Body listed in the International Aerospace Quality Group (IAQG) OASIS database.http://www.iaqg.sae.org/servlets/index?PORTAL_C ODE=IAQG *Note: 9100 includes all IAQG sanctioned standards including but not limited to AS9100C, EN9100 and JISQ 9100. **Note: 9110 includes all IAQG sanctioned standards Including but not limited to AS/EN 9110.

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

Appendix B - Phased Out

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The Boeing Company currently does not recognize AS9003 for production approvals, it has been phased out over time and therefore this Appendix is considered "Obsolete". AS/EN/JISQ9100* is the preferred quality management system standard. *Note: 9100 includes all IAQG sanctioned standards including but not limited to AS9100C, EN9100 and JISQ 9100.

Appendix C - AS9110, Quality Management Systems Requirements for Aviation Maintenance Organizations
o

This appendix describes the quality management system requirements for Boeing suppliers as contained in ISO 9001 as supplemented by 9110*. Appendix C represents the international aerospace quality standard for aerospace maintenance organizations. The Boeing Company has adopted the AS9110* transition timeline as sanctioned by the International Aerospace Quality Group (IAQG). Transition for Appendix C will be in accordance with the schedule on the OASIS database.http://www.iaqg.sae.org/servlets/index?PORTAL_C ODE=IAQG Suppliers that have active contracts for the maintenance, repair or overhaul of nonoriginal equipment manufacturer equipment with Boeing and receive purchase contracts changes or new purchase contracts that include D6-82479 Appendix C as a requirement shall be an AS/EN 9110*,

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

"Quality Management Systems - Requirements for Aviation Maintenance Organizations" certified by an accredited Certification Body listed in the International Aerospace Quality Group's (IAQG) OASIS database: http://www.iaqg.sae.org/servlets/index?PORTAL_ CODE=IAQG *Note: 9110 includes all IAQG sanctioned standards including but not limited to AS9110 and EN9110

Appendix D - AS9120, Quality Management Systems ? Requirements for Aviation, Space and Defense Distributors
o

This appendix describes the quality management system requirements for Boeing suppliers as contained in ISO 9001 as supplemented by 9120*. The Boeing Company has adopted the AS/EN/JISQ 9120* transition timeline as sanctioned by the International Aerospace Quality Group (IAQG). Transition will be in accordance with the schedule referenced on the OASIS database.http://www.iaqg.sae.org/servlets/index?PORTAL_C ODE=IAQG Boeing Appendix D suppliers will be AS/EN/JISQ 9120*, "Quality Management Systems - Requirements for Aviation, Space and Defense Distributors" certified by an accredited Certification Body listed in the International Aerospace Quality Group's (IAQG) OASIS database. http://www.iaqg.sae.org/servlets/index?PORTAL_ CODE=IAQG

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

*Note: 9120 includes all IAQG sanctioned standards including but not limited to AS9120, EN9120 and JISQ 9120.

Addendum 1 - Variation Management of Key Characteristics (9103**)

o

Addendum 1 describes a process for managing the variation of key characteristics (KCs). It includes requirements that emphasize establishing both statistical control and capability of KCs, identification of improvement opportunities and implementation of improvement actions.

**NOTE: 9103 includes all IAQG sanctioned standards including but not limited to AS9103, EN9103 and JISQ 9103.

Addendum 2 - Quality System Requirements for Deliverable Software

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Addendum 2 includes aerospace requirements for deliverable software which have been separated into two sections. Suppliers shall select and declare in their quality manual, which section they will deploy to meet the Addendum 2 requirement. Section 1 is based upon Section 1 is based upon AS/EN/JISQ 9100* and AS9006 (pre-transition) and will be based upon AS/EN/JISQ 9100* and AS9115 when the 9100* transition has been completed. Suppliers Section 1 transition activity must also include transition to the requirements defined in AS9115.

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

Section 2 is based upon the AS/EN/JISQ 9100* and Software Engineering Institute (SEI) Capability Maturity Model Integrated (CMMI). The Boeing Company has adopted the AS/EN/JISQ 9100* transition timeline as sanctioned by the International Aerospace Quality Group (IAQG). Transition will be in accordance with the schedule referenced on the OASIS database. http://www.iaqg.sae.org/servlets/index?PORTAL_C ODE=IAQG *Note: 9100 includes all IAQG sanctioned standards including but not limited to AS9100C, EN9100 and JISQ 9100.

ICOP Certification The Boeing Company promotes and encourages suppliers to obtain Aerospace Quality Management System (AQMS) certification/registration from an accredited industry controlled other party (ICOP) as means of showing compliance to BQMS, Appendix A, C or D requirements (i.e., AS9100, AS9110 or AS9120).

Boeing Recognition of Accredited Aerospace Quality Management System (AQMS) Certification/Registration Requirements International Aerospace Quality Group (IAQG) On Line Aerospace Supplier Information System (OASIS) Website RABQSA International ANSI-ASQ National Accreditation Board International Aerospace Quality Group (IAQG) Related Sites Request for additional information or ICOP questions can be

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.

submitted to the following: grpcrboversightrep@boeing.com.

Overview Our commitment to steady, long-term improvement in our products and processes is the cornerstone of our business strategy. Maintaining customer satisfaction and enhancing shareholder value is a mutual goal of both Boeing and its suppliers. To achieve this objective, we must continuously work together to improve the overall efficiency and productivity of our design, manufacturing, administrative, and support organizations.