Computer Allows "Virtual" Assembly

Leaders of Boeing's 787 program rolled out their first Dreamliner on Wednesday. If that sounds just a bit ahead of schedule, you're right. We should add Boeing did so "virtually," using an advanced software program that recreates the assembly of the company's upcoming composite airliner, entirely on the computer.

"Today's virtual rollout is the culmination of many months of effort by thousands of team members at Boeing and its 787 partners," said Mike Bair, vice president and general manager of the 787 program. "Through the use of our new digital toolset, provided by Dassault Systemes, the team has proven the ability to manufacture 787 designs."

Boeing says the powerful computer system has helped the planemaker cut development costs by 20 percent... and had trimmed a full year from production. It allows engineers to make sure parts will fit together on the actual assembly line, and even tells officials how far a technician will have to stretch to reach a particular bolt.

"The engineering data behind these simulations gives us confidence in our assembly processes and our ability to meet our commitments to our customers," Bair said. "Our tools have enabled us to model the entire production process from our partners' factories to our own. We have found errors in simulation that would have been costly to find in production and have been able to design corrections quickly to keep the program on track."

Boeing says the Dreamliner is set to fly next August, with deliveries starting in 2008. The company is still working to reduce the 787's target weight... another task the computer can help with.

In related news, Boeing also unveiled the new paint scheme for its 747-400 Large Cargo Freighters (below), that will carry large segments of the 787 produced overseas to Everett for assembly. Those airplanes will be named "Dreamlifters." (ANN understands the name "Cessna Swatter" garnered very few votes -- Ed.)

"The Dreamlifter is a vital tool that allows us to create a production flow around the world that is very efficient," said Bair. "We look forward to receiving the second Dreamlifter from EGAT in Taiwan early next month. It will arrive in Seattle already painted and ready to participate in the ongoing flight test program."

FMI: www.boeing.com