Production and management challenges in Boeing's 787 versus 777 programs

¶ … Boeing 777 and 787 Programs

Over the last several years, Boeing has a faced a number of different challenges surrounding the launch of the 787. As the construction of the plane and its management, has contributed to a number of problems. This has led to a host of delays and slowdowns, which has forced the company to address these issues. A recent example of this can be seen with the plane failing a preflight stress test of its wings. This is problematic, because it follows a host of other issues that have been experienced by the 787 (since it was first announced in 2005). (Mecham

2009) (Commercial Airplanes 2011) Evidence of this can be seen by looking no further, than the company being forced to examine a number of challenges they were facing, surrounding the stabilizers in the tail of the aircraft. Where, production was delayed in order to address a fatal flaw that affected the stability of the plane during flight. (Problem in the Workhorse 2009)This is important, because it shows how Boeing has clearly lost its focus, in comparison with other projects that they have worked on in the past. As the 777 was delivered, within four years of the announcement of the first prototype that was constructed. (Commercial Airplanes 2011) This is troubling, because it is highlighting a number of different flaws on the 787 in comparison with the 777. To determine the overall extent of the problems on the 787 requires comparing the production procedures surrounding the two aircraft. This will be accomplished through: examining the construction process, work sharing and looking at the parts / resources that were used. Together, these different elements will provide the greatest insights, as to the underlying reasons why the 787 has continued to face so many problems.

The Construction Process

The construction process for the 777 and 787 were different. In the case of the 777, the company wanted to create an aircraft that could address the challenges facing commercial aviation. What happened was many experts felt that the 747 was the answer to carrying large numbers of: passengers and cargo over vast distances. Since it was introduced in the late 1960's, it would become the preferred aircraft of choice for: a number of carriers around the world. However, Boeing executives believed that a new kind of plane needs to be created, to address the potential shortfalls in 747 production (as the model and the fleet were becoming older). To tackle these challenges and improve upon the innovations that have taken place from the 1960's onward. The company would involve a number of individuals during the design process to include: passengers, aviation experts, company executives, regulators and pilots. This was the first time that they were using collaboration, to design a plane that was going into mass production. The overall process would help to outline an aircraft that had a number of different state of the art features to include: a one of kind cross section of fuselage, the use of LCD crystals, two powerful engines and ensuing that the different components would not account for 10% of the weight of the aircraft. These elements are important, because they are showing how collaboration would help to identify a number of features that would make the plane so successful. Where, the company began to receive large orders for the plane; once the first prototype was announced. (the Making of the Boeing 777-2000)

The construction of the 787 involved the use of outside suppliers to build the majority of the parts for the aircraft (as the company would outsource nearly 80% this work). This is against the traditional policy that was utilized in the past, as Boeing would construct at least 51% of the parts in house. The idea was to have these different suppliers ship the parts to the Everett, Washington facility (where the actual plane would be constructed). At the same time, the company would create new manufacturing plants in: Italy, Japan and South Carolina to deal with various components they were producing. The reason why Boeing made such a dramatic shift from their traditional strategies is because the 787 was suppose to be a major breakthrough innovation wise. Where, the company would implement a number of different features into the aircraft to include: the use of light weight / durable materials, the latest technology, a streamlined air designed and greater amounts of in cabin comfort. This would reduce the costs of: the airplane, improve the overall quality and it became more fuel efficient. These different elements are important, because they are showing how Boeing wanted to create a light weight plane that had the same kind of durability as previous models. As a result, the construction of the aircraft was dramatically altered to be in line with these objectives. (Dream Liner 101-2010)

As far as the design of the aircraft is concerned, Boeing made a number of different changes. What happened is engineers would dramatically alter the blueprints of the new 787. As they would implement a number of different features that were suppose to make it more efficient and powerful. This meant that a various changes took place throughout the aircraft to include: modifications to the wings, the fuselage, the tail section and the nose just to name a few. A good example of this can be seen in the fuselage, where the plane was made with a special kind of aluminum that was designed to increase its performance. This would give the aircraft: better fuel economy, it could travel at higher speeds and further distances. As these new improvements were suppose to help make the plane one of the most state of the art designs that could compete directly against EDS. This is important, because it show how there were dramatic changes to the blue prints during the construction process (which had an impact upon the number of challenges it faced when it was manufactured). In many ways, one could argue that this is what is helping contribute to the inevitable delays. (Ostrower 2010)

When you step back and analyze the construction process, it is clear that Boeing was trying to continue to build off the success that it had with the 777 (when designing and constructing the 787). However, during this process the company did not use as much collaboration (in comparison with the 777) and they outsourced the majority of the component construction. This is problematic, because it shows how these two factors would contribute directly to design flaws in the 787.

Parts / Resources

On the Boeing 777 there are a number of different parts / resources that are implemented into the aircraft these include: the use of aluminum / titanium, a stronger carbon fiber epoxy, utilizing micro balloons and the dual engines. The use of aluminum / titanium helped to create a lighter and stronger aircraft, by allowing engineers to create alloys that were resistant to extreme changes in temperature. While, making the plane lighter and able withstand adverse conditions in a host of environments. A stronger carbon fiber epoxy would help to the company to reduce costs and improve the strength of various plates / other parts that were glued together. Utilizing micro balloons is when Boeing would eliminate the use of sealants, by placing various micro balloons in their place (reducing the weight and strengthening the joints). The dual engines helped to give the 777 greater amounts of: power and range to fly farther distances. These different elements are important, because it is showing how the use of parts / resources would improve the quality of the plane. While at the same time, it is reducing the weight and costs of the aircraft. (Smith 2003)

The different parts / resources that were utilized on the 787 include: a choice of engines, the use of aluminum / titanium and carbon fiber composites. The choice of engines is where customers have the option of using: the GE manufactured engines or those by Rolls Royce. The use of aluminum / titanium is: designed to maintain the high levels of strength and light weight features of previous models (like the 777). New carbon fiber composites were used to increase the strength to weight ratio, while reducing the amount drag on the aircraft. These different elements are important, because they are showing how Boeing tried to improve the design and lighten the weight of the plane. (the 787 Family 2011)

When you step back and analyze the use of parts / resources, it is obvious that this helped to improve the designs of both aircraft. While at the same time, it is help them to be able to decrease the overall amounts of drag and weight. As a result, these components helped make the aircraft stronger and more durable.

Clearly, the main reason why the 787 has faced so many problems in comparison with the 777 is because of: less collaboration and outsourcing. Less collaboration among a host of different parties contributed to the lack of: innovations and design features that were important to everyone. This is problematic, because it meant that a number of these elements were ignored, in comparison with previous models that have been produced by Boeing. While the increased amounts of outsourcing, caused the overall quality of the components that are being produce to: be less reliable and they did not fit with the other pieces. This is because, the various companies that were constructing these parts were not involved in the design process. At which point, they would construct it according to: specifications and not think about if this would work well as a part of the actual plane. As a result, this would contribute to a number of challenges the company was facing when constructing the 787 (with the increasing the amounts design problems). This is important, because it is showing how the lack of collaboration and increased used of outsourcing, contributed directly to various issues that have been experienced, by the 777 in comparison with the 787. Therefore, these are the main reason why the aircraft continues to face so many difficulties.