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  • The iPad and Dreamliner Economy, Redux

    787ipad.jpgNot long ago, a Forbes.com article titled The iPad and Dreamliner Economy discussed the innovation that was taking place inside the US and why domestic technological innovation was far from a standstill.

    While the article reads like a litany of US brands the author’s firm likely holds an interest in, the article’s title is what grabbed my attention. It suggests something far beyond domestic technological innovation, which, I should add, is a monopoly held by no one country.

    Apple and Boeing similarities have cropped up for years in subtle ways in the form of holistic product branding, an emphasis on user experience through “must-have” hardware, and even – most recently – the companies’ quality procedures. Though at its deepest level, the disparate supply chains of both companies anchor the business models of their flagship products.

    A New York Times article exploring the iPhone supply chain through China grabbed my attention this long weekend and the aerospace parallels (and their implications) could be significant. 

    What the latest analysis shows is that the smallest part of Apple’s costs are here in Shenzhen, where assembly-line workers snap together things like microchips from Germany and Korea, American-made chips that pull in Wi-Fi or cellphone signals, a touch-screen module from Taiwan and more than 100 other components.

    But what it does not reveal is that manufacturing in China is about to get far more expensive. Soaring labor costs caused by worker shortages and unrest, a strengthening Chinese currency that makes exports more expensive, and inflation and rising housing costs are all threatening to sharply increase the cost of making devices like notebook computers, digital cameras and smartphones.

    Airframers are perpetually jockeying for position in China’s rapidly growing market; moving component and structural assembly to achieve significant cost savings with lower labor rates while cultivating market access for state controlled airlines to select their fleets accordingly. Even homegrown final assembly lines set up by Airbus (Tianjin) and Embraer (Harbin) avoid high import tariffs while delivering directly to Chinese fleets.

    But how will this shift to higher wages and inflation impact the aerospace industry at large?

    The list of Chinese content on western jetliners is continually growing and will, for example, eventually include 5% of the A350, the center fuselage of the CSeries, the rudder, vertical stabilizer leading edge and outer wing-to-body fairing panels of the 787, as well as the horizontal stabilizer, inboard flaps, ailerons and spoilers of the 747-8.

    The rising labor rates for consumer electronics production may or may not translate to higher wages for higher skilled manufacturing jobs in China, though the increased costs of doing business could shift the dynamic for increasing workshare.

    The tilted playing field toward low labor costs, driven by an undervalued currency, and strategic market access made the shift East a virtual necessity. Though if rising labor costs, which still may be competitive against western wage rates, significantly increase the cost of doing business in China, how will this impact the shape of aerospace supply chains in the future?

    This will be a trend to watch.

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • Photo of Note: 787 prepares to stretch its wings across the Atlantic

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    Boeing went a little shutter happy on ZA005’s first flight in June, taking advantage of the good weather that was elusive during ZA001’s first flight on that afternoon in December. The result, which the company has made into a printable poster (PDF) for its arrival at Farnborough later this month, is a unique angle on the aircraft’s 197ft wingspan.

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • Boeing and Alenia respond to questions on 787 manufacturing quality (Update1)

    ROME — On our visit Wednesday in Grottaglie, Italy, we had a chance to discuss the horiztontal stabilizer inspections with Boeing and Alenia, who fabricates the 787’s tail feathers in Foggia, Italy. The complete responses of Daniele Romiti, Alenia Aeronautica chief operating officer and Bob Noble, Boeing vice president, 787 supplier management are below.
    I’m wrapping up my visit here in Italy this week, heading back to the States on Sunday, and after some technical difficulties that resulted in a corrupted audio file, I found a workaround that allowed me to transcribe the responses to questions regarding the horizontal stabilizer quality issue. Apologies for the belated post.

    Q: With all the issues cropping up in the supply chain from Italy, is Alenia its weakest link?

    Q: How was the issue first discovered? Over the course of the 25 shipsets that made it to Everett, just being found at that point in the quality system, what has been done to make sure this doesn’t happen in the future? And what’s being done to make sure this doesn’t happen in the future?

    Q: Can you tell us what the quality control procedures are within Alenia, how it works with Boeing, how it works at Seattle?

    Daniele Romiti, chief operating officer, Alenia Aeronautica:
    We talk about this, let me call it a manufacturing problem, which is fixed and we used to fixed this with Boeing, as we work as a single team on these subjects, so I think it’s quite normal, I would say even though, I was not happy it even happened, we should say it’s normal in a manufacturing process and is not related even to those new technologies, it was during assembly of spacements, secondary spacements, on the main spar. So, we have fixed it together with Boeing and there is activity ongoing to just complete our repairs on the aircraft.

    Bob Noble, vice president, 787 supplier management, Boeing:
    The defect was found in Everett during a routine inspection. I don’t believe we have inspected every horizontal yet, however, this defect is not on every unit. We’re still working our way through, which units that have the defect and which ones don’t. I wouldn’t characterize it…Alenia is not the weakest link in the 787 supply chain.

    It is a complicated supply chain, Alenia, as you’re going to see, builds a very complicated part of the airplane. Unfortunately you won’t see the horizontal here (in Grottaglie), I know that’s of current interest, but what you’re going to see is this is a very complicated manufacturing process, and unfortunately, periodically, things happen, that’s why we perform so many inspections.

    You asked about the inspection processes, Alenia has an approved quality system, that has inspections for defects, it as a part of that system, Boeing, also provides inspection of the units before they leave Italy. And of course, we also inspect the unit when we received it in Everett, and we inspect it periodically during the manufacturing process.

    Unfortunately, every once in a while, something of this complexity will have an escape, they’re very unfortunate when they happen. This is not at all related to the material system, it is not related to the quality system, it is just one of those things that happens during a manufacturing process. We know what it is, it won’t happen again. Absolutely, positively certain we won’t have that same defect again. We have put counter measures in place to assure ourselves of that.

    UPDATE: I also went back and listened to additional recordings done separately from the main briefings. I asked Bob Noble a question about the processes that are triggered by such a workmanship issue. Here was his reply:

    So what happens when you have something like that you look at all similar things, in fact, we’ll look at all similar things throughout the world. So the shim is in a join, so this will cause us to go back and look at all of our joins and make sure the similar thing can’t happen anywhere else. And we don’t see any evidence of it, this is a unique workmanship issue.

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • Dreamliner: An Italian interpretation

    GROTTAGLIE — Buon giorno from Italy! Just arrived here at Alenia Aeronautica for a day of briefings. The painting above is in the lobby here and it is a wonderfully Italian interpretation of the 787. Lots going on here today. Stay tuned.

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • Travel Night: IAD-FCO

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    Travel Night: IAD-FCO, originally uploaded by flightblogger.

    I’ve got an overnight leg from Dulles to Rome for a visit this week to Alenia. Needless to say my list of questions is very long after the events of the past week. Boeing has been making all the public comments about the horizontal stabilizer workmanship issues and this will be the first chance for Alenia to address it directly.

    My ride tonight is a United Airlines 777-200 (ship 2372 reg?) on flight 966 to Rome. On a semi-related note, 6,300 words on 747-8 and 787 for the Farnborough Air Show edition of the magazine that comes out July 12. Once it’s released, I’ll have additional coverage here on the blog ahead of the biggest air show of the year that will feature the international debut of 787.

    Catch you in Italia.

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • ZA002 returns to testing, ZA003 flies home to Seattle for further inspections

    Boeing conducted inspections Friday of the 787 horizontal stabilizers on ZA002 and ZA003, the only two 787s not in layup. Both returned to flying on Sunday, but with different purposes.

    ZA002 used Sunday to conduct autopilot functional tests, while ZA003, which has been based at Pinal Air Park in Marana, Arizona for high intensity radio frequency (HIRF) testing, returned home to Boeing Field in Seattle. 
    Program sources indicate that following the aircraft’s Sunday return to Boeing Field, ZA003 was set to continue horizontal stabilizer inspections, potentially indicating discovery and further diagnosis of scope of the improperly installed shims and over-torqued fasteners.  
    Boeing declined to comment on ZA003’s return from Marana, citing a policy not to discuss flight test operations. 
    Program sources also indicate that flight tests that were previously assigned to ZA003 late last week have been reassigned to ZA002 for testing on Monday. ZA005, the GEnx-1B-powered 787, is expected to make its second flight Monday as well.

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • First Korean Air A380 peeks out in Toulouse

    KoreanA380-Toulouse_560.jpgIf there’s one thing in aviation that remains constant, no matter what side of the Atlantic (or Pacific) you find yourself on, spotters love the chance to peek between cracked hangar doors. In Toulouse, the Korean Air’s first A380 (MSN035) was spotted in one of the final assembly hangars. The South Korean carrier is quickly stocking up on jumbos and superjumbos as this photo was snapped just a few says after the first (and second) Korean Air Cargo 747-8F made its flight line debut in Everett. See the complete A380 photo.

    A big hat tip to aeroweb-fr.net and a380production.com.

    Photo Credit David Barrie

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • A Sunday must read: Seattle Times on composites

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    I know it’s already Monday in Asia, but add this to your reading list. The Seattle Times has published a lengthy look at the crash impact and fire characteristics of the 787’s composite fuselage, a piece has been in the works for several years. The article includes some interesting new information about the evolution of the structure of the aircraft and its progressive crumple design in the lower portions of the aircraft, along with the concerns raised throughout the aircraft’s design.

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • 787 makes first appearance in Google Maps

    This is notable for no other reason than I thought it would make for a good Saturday morning post. The first 787, ZA001, has shown up on Google Maps for the first time. The photo was taken while the aircraft was in the middle of gauntlet testing. Best I can tell, the satellite photo was snapped sometime between May 16 and June 15 of last year. ZA001 moved to Stall 105 (pictured) on May 16 and ZA002 went to the flight line on June 16, with my best bet putting it sometime around May 25, based on the unpainted Air France 777-300ER, Emirates SkyCargo and un-marked Air France 777Fs parked to the south.

    That being said, here’s the latest on the horizontal stabilizer issues and new delivery re-sequencing that is set to begin in September following the delivery of Airplane 27.
    Also, it’s been three years since roll out.

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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

  • Gaps in horizontal stabilizer prompt another Alenia 787 quality issue

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    Seattle Times aerospace reporter Dominic Gates reported this afternoon that structural gaps in the 787’s horizontal stabilizer have forced the imposition of a reduce operating flight envelope on the five 787 flight test aircraft.

    Here’s my complete story on the horizontal stabilizer, which explains the problem in a bit more depth and why the improper shims and over-torqued fasteners are a problem for long term fatigue.

    This is not the first time Alenia, who makes the horizontal stabilzer in Foggia, Italy, has had issues with its quality control processes. Almost exactly a year ago, Boeing halted production in Gottaglie where Sections 44 and 46 are produced, following the discovery of wrinkles created during manufacturing.

    Boeing maintains that despite a decision not to fly again until the inspections are complete, the 787 fleet is not formally grounded, as the operating limitations will enable test flights to continue if problems are discovered. As you can see from the photo above, 787s on the flight line have
    already been prepared for the inspections with the removal of the
    elevators.

    Photo Credit Liz Matzelle

    This post was originally published to the internet between 2007 and 2012. Links, images, and embedded media from that era may no longer function as intended.

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