When we set out to build a replacement airplane for the 767, we committed to make a generational leap in the design, production and support of airplanes. The extraordinary validation of the 787 in the market testifies to operator and financier confidence that we were right on target on all three counts. The glare of publicity about revolutionary use of composites, open systems architecture and GoldCare support have, to a large extent, obscured the equally profound transformation of airplane manufacturing that the 787 program ushers in.
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Walt Skowronski
President
Boeing Capital Corporation |
Building large sections of the airplane as single, integrated structures transforms the assembly line. Portable tools move assemblies into place without the need for overhead cranes. With fewer parts coming together in final assembly, there is less scrap and significantly less use of hazardous materials. Lean manufacturing improvements produce a more standard product and will ultimately allow us to assemble a 787 in three days, compared to the several weeks required using conventional techniques.
Reinventing airplane manufacturing is not without risks. In October, we were disappointed to announce a slide in the program’s initial deliveries. Additional time to resolve issues, including supply chain bottlenecks, will help get the new production system up and running.
By the end of December, the production line was fully loaded with airplanes. We are confident that the 787 is the right airplane for the market and that our new global production system is the right way to manufacture airplanes in the 21st century.
The 787 global production system embodies the most complete implementation of lean principles that have proven invaluable on our existing product lines. Standardization is central to these principles. Designing a more standardized airplane streamlines manufacturing processes for us and our suppliers. This in turn allows us to share both the risks and rewards of airplane manufacturing more proportionately among all stakeholders.
This new level of collaboration will reduce assembly time and enhance quality. And, because standard airplanes share standard maintenance and modification procedures, they retain their value in the market and enjoy greater liquidity as assets.
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