Third Flight-Test Airplane Loaded into First Position

They're not flying 'em yet... but Boeing is making progress with building 'em. Final assembly began this week on the third flight-test Boeing 787 Dreamliner, the first plane that will sport a finished interior.

As ANN reported, Boeing announced a third delay to the 787 program last month, due to continued problems with components received from suppliers, unanticipated rework, and the addition of a margin into the testing schedule. First flight of the composite-bodied airplane moved to the fourth quarter of 2008, rather than the end of the second quarter, and first delivery is now planned for the third quarter of 2009 instead of first quarter.

While the planemaker continues to work towards putting a Dreamliner in the air, Boeing notes this is the fifth Dreamliner to be loaded into the first position of the 787 production system. The static test airframe moved April 25 from the Final Assembly to its test rig in another bay of the Everett, WA-based factory.

Both the fatigue test airframe and the second flight-test airplane have advanced to the next position in production, where assembly and systems installation work continues... further signs that early supplier issues and production snags are, ever-so-slowly, being ironed out.

"We are receiving assemblies that are much more complete," said Jack Jones, vice president of 787 Final Assembly and Change Incorporation. Jones replaces Steve Westby, who retired from Boeing yesterday after a 31-year career. "The second flight-test airplane had a 50 percent reduction in the amount of incomplete work as compared to the first airplane. 'Traveled work' on this airplane is 65 percent less than on the first."

After assembly is complete, this airplane will be fitted with an interior as part of the comprehensive flight-test program and certification process.

"When that happens this summer, it will be the first time we'll see the 787 in what is close to a final delivery configuration," Jones said.

The first airplane to fly is on track for "power on" in June.

FMI: www.boeing.com