Passing the Value TestThe Boeing Technology Advantage
The real value of technology springs from the innovative application of the latest advances to create new ways for airlines to earn revenue and conduct business, and to help passengers rediscover the joy of flight. Such innovation may show up as new airplane capabilities and features, or it may take the form of better ways to produce the airplane in the factory. Both types of innovation focus on reducing the cost of owning and operating the Boeing 787 Dreamliner. Technology builds value aboard the airplaneThe Dreamliner introduces major advances in four areas of airplane design: use of composite materials for primary aircraft structure, replacing pneumatics with electrically powered systems, increased commonality and interchangeability through open systems architecture, and enhanced aerodynamics. Composite Materials: Unlike any other commercial airplane, 50 % (by weight) of the Dreamliner's structure is made of advanced carbon composite materials. Carbon composites are strong, yet lightweight. They are resistant to the fatigue that eventually causes metal structure to weaken and crack. And 30 years of aerospace use shows that carbon composites are immune to corrosion. The 787 uses composites where the material's superior damage resistance provides everyday operational benefits, simplifying service and maintenance and eliminating inspection requirements. This makes the Dreamliner more valuable to airlines because it costs less to operate and is available for more hours of revenue service.  More-electric Systems: Recent advances in electric motor technology provide another opportunity to create value. In the 787, most onboard mechanical systems are powered by electric motors. Conventional airplanes rely on bulky and complex pneumatic systems, powered by hot, high-pressure air diverted from the airplane's engines. Pneumatic systems on conventional airplanes require a complex system of manifolds, valves, and ducts to power secondary systems located throughout the airplane. These systems require constant monitoring and frequent maintenance. On the other hand, the Dreamliner uses wires with simple plugs and sockets to distribute electrical power from generators to electric motors that are compact, efficient, and reliable. These electrical systems are monitored automatically by the airplane's central maintenance computer.
On the Dreamliner, all the high-speed air produced by the engines goes to thrust. So, more of the airplane's fuel goes to flying and less goes to heating the coffee, keeping the cabin comfortable, and all the other things that electricity does more efficiently than pressurized air. And, because electrical systems are inherently easier to service, upgrade, and relocate, owners and leasing companies can quickly reconfigure an airplane for a new owner or operator. Open System Architecture: The way onboard systems are installed to interact with each other is yet another major area where innovative use of technology creates value on the 787. Traditionally, systems manufacturers and suppliers customized their products for each airplane type. Boeing and its partners have adopted an "open" systems architecture for the 787, based on industry-wide standards. This will make it easier for manufacturers to upgrade information systems, such as radios and displays on the flight deck, and even entertainment systems in the passenger cabin. Airplane owners will be able to simply plug in a new component and installation software will integrate the new equipment with the airplane's central computer system. This is also a boon to an airplane owner preparing to sell or lease an airplane to another operator. Aerodynamics: New computer design tools and analytical software allowed engineers to refine the airplane's shape to get the most aerodynamic advantage from the extremely smooth surfaces and graceful curves that composite materials make possible. Boeing has also worked with engine manufacturers to make sure the airplane's wing and aerodynamics gain maximum benefit from new engine technologies and capabilities.
Boeing brought together an international team of composite manufacturers to tackle the problem. The team developed tools that allow large sections of the fuselage barrel to be built as a single piece. Robotic tools apply layers of epoxy-impregnated carbon fiber fabric over precisely configured forms to build up the precise thickness required for the airplane's skin. The cylindrical section is then baked under pressure to create the finished fuselage section, ready for the installation of wiring, systems, and interior provisions. Fully assembled fuselage sections will then be joined in final assembly. Breakthroughs such as these are helping Boeing shrink production times dramatically. Shorter production times reduce the time lag between airplane order and airplane delivery. This, in turn, can help acquisition planners match fleet requirements more precisely and forecast finance and interest costs more confidently. Summary: At Boeing, technology is serious business. The technologies that earned their way aboard the Dreamliner and onto the factory floor have passed the value test. Every one of them will contribute to the Dreamliner's performance and capabilities, to the owner's balance sheet, and to the passenger's enjoyment of flight. Walt Gillette, vice president 787 Program Development, announced his retirement, effective July 31, 2006, after 39 years of service to Boeing and the commercial aviation industry. Scott Strode, currently vice president of Airplane Production, will succeed Gillette.
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