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FAA To Investigate 787 Dreamliner

Dupple sends word from the BBC that the U.S. Federal Aviation Administration will be conducting a safety review of the Boeing 787 Dreamliner after a number of incidents have called the aircraft's hardiness into question. "An electrical fire, a brake problem, a fuel spill and cracks in the cockpit's windshield have affected Dreamliner flights in the past week. ... The Boeing 787 Dreamliner is one of the most advanced aeroplanes ever created. Much of it is made from very strong, light carbon-fibre composite material. However, a spate of technical issues has hurt its image. On Friday, two new problems were found, adding to Boeing's woes." A spokesman for Boeing said they were "absolutely confident in the reliability and performance of the 787," and were cooperating fully with the FAA's investigation. The 787 went into service in 2011, and 50 have been delivered to various airlines since then, with hundreds more on order. Qatar Airways has received five of them, and it has criticized Boeing for manufacturing faults.

38 of 237 comments (clear)

  1. Outsourcing Manufacturing by Liquidretro · · Score: 5, Interesting

    I wonder if the manufacturing and quality problems has anything to do with the change on this plane that it is made all over the world, by tons of suppliers, then all moved to a common location for final assembly. This is a departure from the way Boeing has done manufacture in the past where most things are done under one roof.

    1. Re:Outsourcing Manufacturing by girlintraining · · Score: 5, Interesting

      Possibly. But a lot of cars are built that way too, and while a process change for a business invariably has kinks to work out, that doesn't mean the move was the wrong one. Boeing was hemmoraging cash up until recently, and this switchover may save them a lot of money at the cost of some run-up problems.

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    2. Re:Outsourcing Manufacturing by Frosty+Piss · · Score: 4, Interesting

      Possibly. But a lot of cars are built that way too

      True, but note that in fact there are many many "recalls" for critical problems with autos every year. Yet there is a difference between an auto traveling on a surface road with 2 or 6 passengers, and a jet at 30,000 with 200 passengers. When one catches fire, it's going to be a little more catistropic than the other...

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    3. Re:Outsourcing Manufacturing by DerekLyons · · Score: 4, Insightful

      This is a departure from the way Boeing has done manufacture in the past where most things are done under one roof.

      Boeing has been making parts in one place, from small ones like doors or control surfaces all the way up to entire fuselages, and shipping them to another for final assembly for many years now.

      They started assembling 737 fuselages in Wichita and then shipping them by rail to Renton for final assembly back in the 80's. The production of smaller bits (doors, seats, empennage, etc...) overseas (notably in China and Israel) started back in the 90's. (And was a huge issue in one of the machinists strikes.)

    4. Re:Outsourcing Manufacturing by girlintraining · · Score: 4, Insightful

      True, but note that in fact there are many many "recalls" for critical problems with autos every year. Yet there is a difference between an auto traveling on a surface road with 2 or 6 passengers, and a jet at 30,000 with 200 passengers. When one catches fire, it's going to be a little more catistropic than the other...

      An apples to oranges comparison. I'm referring to the efficiency of the manufacturing process. You're referring to problems with the engineering and design process. Airplanes like this are built one part, one section, one plane, at a time. There's numerous qualifications and tests done at each stage of assembly. And the models don't change year over year, unlike cars. The 787 is being produced with interchangeable parts and have the same general appearance, function, and specifications, as the ones 5 or 10 years from now will.

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    5. Re:Outsourcing Manufacturing by Richard_at_work · · Score: 5, Informative

      The difference is that the 787 is the first aircraft Boeing has attempted to build pre-stuffed fuselage sections off-site for, and assemble them into a completed aircraft at the FAL. Airbus has been doing this since the early 1980s, but Boeing still used their on-site build process for the 777 in the 1990s.

      Boeings mistake was in changing the production methodology at the same time as changing the technologies involved - a switch to a higher aluminium content electrical wiring and the differing tolerances of such a move, new ways of grounding, new materials etc etc. suddenly the same assembly workers have to adjust not only their working practices but their skill set as well.

    6. Re:Outsourcing Manufacturing by Anonymous Coward · · Score: 5, Interesting

      I wonder if the manufacturing and quality problems has anything to do with the change on this plane that it is made all over the world, by tons of suppliers, then all moved to a common location for final assembly.

      I think an even bigger problem is the way that the engineering was outsourced (whether domestic or foreign outsourcing). Even Boeing management eventually admitted they screwed the pooch on that one. In many cases subcontractors that were capable of manufacturing good parts were suddenly given the responsibility of designing them - an area where they had little expertise. There was also poor coordination between Boeing and these subcontractors. The only way they got this pig up in the air is by finally bringing in a bunch of engineers who had deep expertise in designing airliners. Surprisingly they found almost all of them at a company called "Boeing". Perhaps they should have used that company's engineering services all along.

      Many of the mistakes made in the 787 design were downright amateurish, such as improper design of the wing attachment points (and extremely critical part of the design that Boeing had figured out decades ago). Though they got enough of these biggies out of the way to get certification, it doesn't surprise me that there are still lots of "little" problems left over.

    7. Re:Outsourcing Manufacturing by mcrbids · · Score: 3, Informative

      Comparing airliners to cars is a terrible, terrible comparison, and not for the reason that many would think.

      Airliners are just ridiculously safe. Statistically speaking, you are safer on your standard 737 jet than you are sitting on your couch, in your living room. Comparing their safety to a car is like comparing the safety of going for a walk in a park to playing with hand grenades.

      In this environment, *any* kind of problem is just intolerable. As much as anything could be, airliners demand perfection, and given peoples' general fear of flying (damn the numbers) it makes sense why.

      BTW: The reason why a jetliner is statistically safer than sitting on your couch is because people near death due to age/disease don't typically fly but they are likely to sit on their couch.

      --
      I have no problem with your religion until you decide it's reason to deprive others of the truth.
    8. Re:Outsourcing Manufacturing by mea_culpa · · Score: 3, Insightful

      It think it has more to do with the MBA culture that has infected businesses in the US like a cancer. The environment this creates cuts out any will to perform better than what is needed to stay employed promoting mediocrity. When this goes on long enough, good talent tends to look for a better habitat.

  2. Not good enough. by serviscope_minor · · Score: 4, Interesting

    It seems that most revoloutionary aircraft have nearly sunk the parent company. The 787 hasn't come close to sinking Boeing, so one can conclude that it's not good enough.

    Sillyness aside, new aircraft always have teeting problems (the A380 blew up an engine during flight) and this is a particularly new and unusual aircraft. So, expect lots of teeting problems.

    They'll probably be great when all those are ironed out.

    That said, I've never seen an explanation as to how to do the equivalent of replacing a skin panel when the skyfood loading truck reverses into the plane.

    --
    SJW n. One who posts facts.
    1. Re:Not good enough. by ibwolf · · Score: 5, Funny

      They'll probably be great when all those are ironed out.

      Or in other words; wait for the first service pack before flying...

    2. Re:Not good enough. by mcgrew · · Score: 4, Interesting

      Indeed, I was stationed at Dover when the first C5-As were rolled out. You wouldn't believe the trouble they had... landing gear not coming up/down, engines falling off, fires, hell even one of the giant cranes that serviced the aircraft's tailsection fell over at another base and killed two guys, grounding the whole fleet of C5s for a few weeks.

      A year or two later they pretty much had all the bugs ironed out. After that the worst that happened was one poor guy I worked with was towing one and hit a hangar door with a wing and did ten million dollars worth of damage (he got off the hook, the wing walker got the blame).

    3. Re:Not good enough. by Anonymous Coward · · Score: 4, Informative

      Thats not what happens. As problems are found and corrected, the FAA issues airworthiness directives (AD) that require the fleet to undergo fixes in a certain amount of time. Sometimes they ground the fleet until all aircraft are fixed.

      Different model numbers usually refer to stretched versions of the same airframe. It cuts costs as stretching the fuselage isn't considered a new aircraft type, so you don't need to go through the whole type certification again. The 787-200 or whatever will carry more people. Airliners are designed with this in mind, engines and wings are oversized for the smaller models, and the type will grow eventually.

      You can see this in the 737. there are 8 or 9 models, all of them are flown under the same type certificate.

    4. Re:Not good enough. by serviscope_minor · · Score: 3, Informative

      Don't confuse the engine with the aircraft. Generally the manufacture recommends an engines, but the customer can pout whatever engine they want' into it.

      Only up to a point. The planes are genrally available with only a very small number of engine options. Also like with many big new aircraft the trent 900's were made specially for the A380. Though of course RR will hope for new customers, too.h

      --
      SJW n. One who posts facts.
    5. Re:Not good enough. by clickclickdrone · · Score: 3, Interesting

      Back in the day my friend's dad used to fly 707's (yes, it's a very old story) and whilst taxiing, they managed to gouge a chunk out a wing. This was at a US airport. They needed to get the plane to Australia to get the replacement wing so they moved the plane somewhere quiet at the airport and duct taped up the wing. They were told to be careful no one saw what they were up to. They then had to take off at night when it was quiet so no one could spot the bodged up wing.
      .
      My friend's dad was good at that sort of thing. Another time he lost 2 of the 4 engines flying over the UK and was told to dump most of his av-gas to lighten the load so he could land in France for repairs. That involved opening valves that let the gas pour out over the wings. It was bad enough he dumped most of his fuel over a populated area (nice, greasy, thanks mate) but he also had to do it in the middle of a raging thunderstorm. He got struck twice whilst doing the dumping. Amazingly, he and the plane survived to fight another day,

      --
      I want a list of atrocities done in your name - Recoil
    6. Re:Not good enough. by Anonymous Coward · · Score: 5, Informative

      You don't use duct tape, you use speed tape, and it is qualified for these kinds of purposes.

      Fuel dump evaporates before it hits the ground.

    7. Re:Not good enough. by serviscope_minor · · Score: 4, Insightful

      Not unbelievable at all.

      Another related anecdote: I know of a structural engineer (friend of a friend) who wanted to photograph an old concrete shell hangar at Heathrow(?) before it was demolished, as it was an excellent example of tension shells.

      Being from Cambridge, he was able to actually get to talk to people who would be able to allow such a thing.

      They refused.

      The reason is that it was full of aircraft in peices. Apparently, the policy is to not let on to the public that aeroplanes come apart and are in fact safe monolithic flying machines. They didn't want the risk of the photos getting out.

      --
      SJW n. One who posts facts.
    8. Re:Not good enough. by clickclickdrone · · Score: 4, Interesting

      Fuel dump evaporates before it hits the ground.

      Fair enough but what's all the greasy residue you get all over your house, car etc if you live near an airport? General exhaust gunk?

      --
      I want a list of atrocities done in your name - Recoil
    9. Re:Not good enough. by SvnLyrBrto · · Score: 3, Informative

      I think you fell victim to a BS-artist's tall tales.

      1) You might want to look into the differences between duct tape and speed tape. The former may make a better storey. But the latter is far, FAR, more likely.

      2) Boeing 707s didn't burn avgas. (They may have been theoretically able to do so. Turbine engines are amazingly tolerant about what they burn, at least in the short term. But certainly no 707/engine combo was rated for avgas.) Like all other civilian turbine-driven aircraft, they were fueled with Jet A in the US, Jet A-1 in most of the rest of the world, and Jet B in extremely cold climates.

      3) The fuel-dump outlets on the 707, and on pretty much every aircraft that has a fuel-dump system (Not all aircraft do.), are on the trailing edge of the wing. Fuel could not be pouring "out over the wings" unless the wing tanks were actually punctured and leaking.

      --
      Imagine all the people...
  3. This was to be expected by whizbang77045 · · Score: 3, Informative
    Whenever you introduce new technology on an aircraft design, you open the door for problems you haven't seen before. If you introduce a lot of new technology, you get a lot of new problems, some of which are almost certain to catch the public eye. Look what happened to Airbus on the A320 some years back!

    They'll no doubt find the problems, but more are likely to occur. Whether Boeing is able to maintain a good image for the airplane is another question.

    1. Re:This was to be expected by Richard_at_work · · Score: 4, Informative

      If your A320 comment is related to the famous crash video, that had nothing to do with the aircraft - it was the pilot which screwed up there.

  4. Re:A true union built aircraft by Frosty+Piss · · Score: 5, Insightful

    Of course your post is both a troll and falimbait.

    The 787 is built from components made around the world, mostly by non-union workers. The Boeing plant in South Carolina that does 787 assembly is non-union.

    You are an idiot.

    --
    If you want news from today, you have to come back tomorrow.
  5. Nothing in the new stuff by Anonymous Coward · · Score: 3, Interesting

    The really new technology is the carbon fibre used in the aircraft. Not seen any reports of faults with that yet though.

  6. 787 is safe. When composite burns it releases... by Futurepower(R) · · Score: 4, Informative

    Balanced information:

    U.S. regulators say Boeing 787 is safe but needs review.

    FAA Orders Review Of Boeing 787 Dreamliner quote: "... we are confident about the safety of this aircraft, but we are concerned about these incidents."

    A bigger issue: When composite burns it releases poisons. I haven't seen any discussion of Boeing's view of that. Here is a PDF file: Postcrash Health Hazards from Burning Aircraft Composites.

    There is NO intent in saying that to imply that a 787 might crash. But if there is a runway or other accident, would passengers be less likely to survive?

  7. Re:A true union built aircraft by Richard_at_work · · Score: 4, Interesting

    Actually, several months of the original 787 delay was down to the IAM union strike in 2008 which shut down the Seattle FAL (although the strike lasted just 8 weeks, the FAL took 3 months to come back up to speed) - the SC FAL was only chosen and built after this strike.

  8. Re:A true union built aircraft by Richard_at_work · · Score: 4, Insightful

    Considering all of the aircraft that have thus far had issues came from the Seattle FAL, I'd say that the union product isn't much better - the fuel system is installed by union workers, it has had several major QA issues, the electrical equipment which was at the centre of the recent issue is installed by union workers.

    I'm not particularly pro or anti union, but the arguments for and against unions in this thread are ridiculous.

  9. Stating the obvious by clickclickdrone · · Score: 3, Interesting

    A spokesman for Boeing said they were "absolutely confident in the reliability and performance of the 787,"

    Why do they ever bother with these quotes - what else are they expected to say? As Mandy Rice Davies once said when asked to comment about a Lord denying he had anything to do with her, "Well, he would, wouldn't he"

    --
    I want a list of atrocities done in your name - Recoil
  10. Re:A true union built aircraft by clickclickdrone · · Score: 4, Insightful

    I'm guessing you're in the US where the role of unions seems a little more unhelpful. I get the impression over there they're all about protecting lazyness and wierd working practices. Elsewhere, they tend to do rather more good, working more constructively with employers and employees.

    --
    I want a list of atrocities done in your name - Recoil
  11. Re:787 is safe. When composite burns it releases.. by MightyYar · · Score: 4, Insightful

    I start my day by inhaling the fumes of jet fuel and aluminum, myself. Would never touch that composite smoke, unless it came from carpet, upholstery, and cabin interior plastics.

    --
    W..w..W - Willy Waterloo washes Warren Wiggins who is washing Waldo Woo.
  12. Re:A true union built aircraft by Anonymous Coward · · Score: 3, Insightful

    Erm, unions are generally a good thing. They protect the worker's rights and keep employers in line. You must be thinking of the neutered version of unions you guys have in the US. Then again, the US is a shithole when it comes to work, so it's not surprising for you to think that way.

  13. Releases poisons - misrepresents the design by ace37 · · Score: 5, Informative

    You seem to be under the impression fires in composite aircraft pose a risk of poisoning or harming passengers.

    It's not that simple though. Composites (FRP) are made from a fiber and a resin, which can be thought of like a glue. Most plastics can be used as a resin. On an aircraft, they use many different resins in different places as they are tailored to the local requirements. Also, these plastics are subjected to a number of tests that are used to determine toxicity in a few reasonable ways; most of them concentrate on what happens when we burn the plastic.

    Near passengers, they have requirements ensuring the parts are self-extinguishing in a short (1 minute) time frame and have no toxicity in their smoke (The flammability test is UL 94, V0 is a typical requirement; I forget the smoke and toxicity test numbers I've used). So the plastic that holds your luggage above your head is made of a less weight-efficient material because it must meet design requirements focused on passenger safety in the event of a cabin fire. And of course, in the middle of the wing, it doesn't much matter if the smoke from a fire would make a passenger sick--passengers aren't anywhere near there--but fuel is probably nearby, so the design requirements and fail-safe measures for flammability and smoke are different there and in other zones of the aircraft.

    In the paper you cited, note that the focus was on emergency response personnel. If as a passenger you're exposed to such an explosion, respiration of the fibers that carry potentially toxic plastics isn't the top concern - if you're inhaling that, I would be wondering what punched a hole in the fuselage and how many people are dead. The respiration and other hazards are a big deal to a ground crew or fire department who would put out non-crash-related fires. But the words in bold, "A bigger issue: When composite burns it releases poisons," are easy to misinterpret as a major passenger safety hazard unique to this aircraft.

  14. Re:A true union built aircraft by MillerHighLife21 · · Score: 4, Insightful

    The idea of unions vs the reality of unions just end up being very different things in the US.

    --
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  15. Re:A true union built aircraft by ethorad · · Score: 4, Informative

    I assume by "Elsewhere they tend to do rather more good" you're not including the UK. Over here in the UK they are also all about protecting lazyness and weird working practices such as holding back modernisation, reinstating bullies, etc

    (I know this is a generalisation, and therefore I'm sure there are exceptions, however the biggies such as train staff in particular and public sector unions fall into this category)

  16. Re:A true union built aircraft by dkleinsc · · Score: 5, Insightful

    I'm guessing you're in the US where the role of unions seems a little more unhelpful. I get the impression over there they're all about protecting lazyness and wierd working practices.

    Let me tell you a recent union-related story, and the public perception of it:
    1. Management goes to the union and says "We need to cut your wages 30% in order to keep the company afloat."
    2. Union agrees.
    3. Management celebrates by giving themselves large bonuses.
    4. 2 years later, management goes to the union and says "We need to cut your wages 50% in order to keep the company afloat."
    5. Union threatens to strike.
    6. Company bankrupt. At least half the public blames the union.

    --
    I am officially gone from /. Long live http://www.soylentnews.com/
  17. Re:A true union built aircraft by sjames · · Score: 4, Informative

    Before concluding that Unions support laziness, consider that workers in the U.S. are generally expected to work more hours with less vacation than the vast majority of the free world. So according to employers, trying to achieve parity with the E.U. is promoting laziness.

    As for weird working practices, for each and every 'crazy' union rule, there is a corresponding previous attempt by management to cheat in some way either to edge the union out or to extract more work than agreed upon or to pay less than agreed upon./

  18. Reversion to mean by sjbe · · Score: 5, Interesting

    Granted, I've never even worked in a union myself

    Nor have I but I'd dealt directly with them almost daily at times. I've had wrenches thrown at me because I dared to produce a stopwatch. (I'm an industrial engineer - that's what we do) I don't hate unions but I think they've forgotten their real purpose and have become far too adversarial with the companies.

    But honestly, if a German union and all its workers were suddenly transported here, with all the time off and other benefits they receive, can you imagine anything but mortal conflict with US management?

    The benefits any pay for workers in certain unions such as the UAW are second to none. I've seen guys with no college degree who make upwards of $80-100K+ for an assembly line job. Until very recently average wages of a GM worker was $39.69/hour and benefits tacked another $33.58/hour on top of that. We're not talking about specialty skilled labor here either. Guys with little to no special skills used to be able to get jobs that paid far better than the requirements of the job dictated. That has proven to be unsustainable.

    Blue collar America has taken an incredible beating with a huge decline in standard of living over the last 30 years, today's auto workers are lucky to make half of what their fathers did.

    Their fathers got a deal that was out of line with what could actually be sustained by the profits of the companies. Blue collar america is simply experiencing a reversion to the mean. They've had a good run for a while and now the bill has come due.

  19. Re:A true union built aircraft by interkin3tic · · Score: 5, Insightful

    6. Company bankrupt. At least half the public blames the union.

    The public arrives at this conclusion, aided in no small part by the conservative media, as part of it's lesson that the noble class is to be catered to in every whim, because that's the only way anyone has jobs.

  20. Re: A true union built aircraft by deathguppie · · Score: 4, Insightful

    I've worked in both union and non union shipyards my whole life. For the past twelve years I've worked non union. As far as quality of work, its tough to say if one is better than the other. As far as qualified journeymen there is no doubt that unions provide people with an already appreciable skill level. Whereas non union yards have an enormous turn over rate. The yards here in Seattle can send someone back to the hall if they feel they are unqualified and if you're sent back from three sequential jobs the union will drop you. The yards get the benefit of qualified workers as well as lower employee medical costs as the group rate covered by the union is lower. On the flip side after nearly thirty years of working in the industry since I have chosen to work non union my pension now amounts to the few thousand dollars I've been able to scrape into my 401k (profit sharing has been offered more than once then stripped again) and I can feel my body slowly deteriorating. There is no job security and as I have seen before when you can no longer produce there will be no more work. I hope every day that my coding skills will get good enough that I will come to the attention of someone, because when I cannot carry 100lbs up a ladder I'm done.

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    once more into the breach