2021 a Mixed Year for the Manufacturer, Finally Cash-Positive, but Tanker and Dreamliner Programs See Setbacks

The 787 Dreamliner's production issues will add at least $2 billion to the cost, said the company, doubling an earlier prediction.

Boeing saw a rebound in demand for its 737 Max airliner over 2021, coming back from a strange year before it that saw the plane grounded nearly worldwide. No sooner had it returned to the public's good graces, however, that its larger sibling faced its own issues. The delays have resulted in additional manufacturing costs, inspections, and compensation for customers still waiting on their planes to be delivered. 

The 787 saw a brief 3-month grounding in 2013 due to its use of then-new lithium-ion batteries which were found to be a little too eager to set themselves aflame. After addressing the issue, the aircraft surged back to popularity, as the two-aisle, twin-engined aircraft combined the best of Boeing's old and new in one. The Dreamliner offers fuel economy and green credentials similar to smaller narrowbody aircraft, owing to its elimination of 2 of its predecessor's engines, but keeps their range, endurance, and overall capacity. 

The newest issue arose when inspection exposed production flaws in late 2020. Gaps, misfitted joints in the composite fuselage and wings were found in some cases, enough to halt deliveries until the issue was analyzed and addressed. After resuming deliveries, Boeing almost just as quickly paused them after discovering faults in titanium parts received from a supplier, a problem which has yet to be addressed to the FAA's approval. The CEO of Boeing, David Calhoun , has described the fix as coming along just fine, telling reporters "The rework process is going well — it's long, it's disciplined, but it's going well, our mechanics are learning a ton in the process.” Earlier this year, United Airlines bemoaned the shortfall in aircraft as they dropped a number of international routes planned for summer of 2022, believing that their expected Dreamliners won't be delivered in time to enter service. Still, Calhoun sounded optimistic in a recent note to staff, telling employees the company was "well positioned to accelerate our progress in 2022 and beyond." 

FMI: www.boeing.com