787 Flight Test Update: Month Three (Plus 7)

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Also See: 787 Flight Test Updates – Month One & Month Two

With three months and seven days since the 787’s December’s first flight, four Dreamliners have taken flight, accumulating roughly 360hr of flight time. Boeing is moving into the heart of its flight test program after completing both flutter and ground effects testing, with Type Inspection Authorization (TIA) by the Federal Aviation Administration expected by month’s end. 

There’s been much discussion about the rate of accumulation of flight hours and whether or not the 787 flight test fleet is flying enough to meet the pace for a fourth quarter entry into service. Flight test hours, while the gauge offered by Boeing on 787flighttest.com, may not be the most accurate representation of the progress of the program. Frank Rasor, director of flight test operations for Boeing, explained last year that simple division will not yield a proper measurement of progress:

The other thing, if you did the math, when we talk about 7000 hours when you add up the ground test and flight test, and that adds up to longer than the flight test duration, if you just did testing. Well, there’s a tremendous amount of concurrency in the test, so one test flight might be checking off 5-6 hours of written test objective. You can’t take that math and divide by 24 and 31 because you’ll get the wrong answer.  

Though month three of 787 flight test did provide a bit of clarity on the pace of hours being accumulated. Boeing Commercial Airplanes CEO, Jim Albaugh, said on March 9th that the program had used some margin built into the flight test program, but declined to specify how much. Albaugh traced the margin use to slower than expected turnaround time and a steeper learning curve.

We did burn a little bit. And, really, what it was– It was really two things – getting the efficiency on the flight test program up. Right now, it’s above where we wanted it to be. And the other thing is getting the turnaround of the airplanes, so we can get the hours in the airplane each and every day. And I think we’ve been able to address that. Again, a little slow in getting up to the learning curve. I think we’re there right now. Last week, we had three airplanes up simultaneously. And I think, at the end of this month, we get our certificate, which will allow us to bring the flight engineers– to bring the FAA onto the airplane and to really get into a lot of testing. So that should happen by the end of this month. 

When Boeing mapped out its 787 flight test plan, it originally targeted TIA – the official commencement of certification – about two months after first flight. Program sources say that TIA was planned for late February. Albaugh’s March 9 assessment places TIA at the end of the month, placing Boeing about a month off of its anticipated pace. Another source says that TIA continues to be paced by the completion of the Wedge V5.5 software testing.
Month Three 787 Flight Test Update continued below

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This post originally appeared at Flightglobal.com from 2007 to 2012.