Boeing 787 - Challenges of Complex Global Systems

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Boeing 787 -Challenges of Complex Global Systems2010 MIT SDM Systems Thinking Conference

Mark JenksVice President, 787 Development

October 21, 2010

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Agenda

Program Overview and History

A Highly Integrated Global System

Leading Globally

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Advancing the State-of-the-Art in Composites Manufacturing

2001 - 2002

2003

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Composites

Historical Use of Composites

1950 1960 1990 2000 2020

35

45

50

25

15

0

% S

truc

tura

l Wei

ght

1970 1980 2010

DC-9B747

A300-600

B777

30

40

20

10

5

A380

?

Composites or Aluminum?

Rec

urrin

g C

ost

Rec

urri

ng C

ost

WeightWeight

1990sComposites

7E7 Composites

Potential

1990sAluminum

Advanced Alloys

PotentialTarget

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Historical Use of Composites

1950 1960 1990 2000 2020

35

45

50

25

15

0

% S

truc

tura

l Wei

ght

1970 1980 2010

DC-9B747

A300-600

B777

30

40

20

10

5

A380

B7E7

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Composite Structure

Lighter

More durable

Negligible corrosion and fatigue

Reduced scheduled maintenance

Opens new design possibilities

Carbon laminateCarbon sandwichOther compositesAluminumTitaniumTitanium/steel/aluminum

Aluminum20%

Titanium15%

Steel10%

Other5%

Composites50%

Composites are the right material choice for the 787

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Delivering on the 787 Vision

FUNDAMENTALINNOVATIONS

BREAKTHROUGHPASSENGEREXPERIENCE

LOWER COSTS,NEW REVENUEOPPORTUNITIES

Composite structureMore electric architectureAdvanced aerodynamicsLatest engine design

Large dimmable windows Lower cabin altitude Smoother ride Cleaner air Dynamic lighting

Same range & speed as current long-range airplanes

Open new non-stop marketsCarry more cargo Fast cruise speed - Mach 0.85 Less maintenance, more productivity Lowest trip cost

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The 787 Expands the Technology Envelope

Composite primary structure Reduced weight Improved fatigue and corrosion properties First heavy maintenance visit at 12 years Enables new design possibilities

New level of aerodynamic efficiency Mach 0.85 cruise with low fuel consumption Smoother ride Advanced flight controls reduce structural loads

Latest engine technology Lower fuel consumption – fewer emissions Smaller noise footprint Reduced maintenance

More electric systems architecture 1.5 MW power generation capacity

Air conditioning Anti-ice Brakes

Improved reliability (V5) More efficient energy usage Comprehensive health monitoring capabilities

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Unprecedented Market Response

*

*

• As of 31 August, 2010* Leasing operator

847 orders from 55 customers

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787 RolloutJuly 8, 2007

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Flight Test Milestone Progress

Expanded TIA | Apr  2010Expanded TIA | Apr  2010 Extreme Weather | Apr 2010Extreme Weather | Apr 2010Icing Testing | May 2010Icing Testing | May 2010

GE First Flight | Jun 2010GE First Flight | Jun 2010GE Flutter | Jul  2010GE Flutter | Jul  2010

Ultimate wing test | Mar 2010Ultimate wing test | Mar 2010

Flutter testing | Mar 2010Flutter testing | Mar 2010Initial airworthiness | Jan  2010Initial airworthiness | Jan  2010Ground effects | Mar 2010Ground effects | Mar 2010

First Flight | Dec  2009First Flight | Dec  2009

More than 620 flights and 1,905 flight hours

RollsRolls‐‐Royce NAMS | May 2010Royce NAMS | May 2010

Flight Load Survey | Sep  2010Flight Load Survey | Sep  2010

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Video

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Everett Final Assembly

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Agenda

Program Overview and History

A Highly Integrated Global System

Leading in Complex Global Systems

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Structures from Around the WorldFuji Heavy IndustriesFuji Heavy Industries Kawasaki Heavy IndustriesKawasaki Heavy Industries

Mitsubishi Heavy IndustriesMitsubishi Heavy Industries

Korean AirKorean AirAlenia AeronauticaAlenia Aeronautica

LatecoereLatecoere

SaabSaab

Messier-DowtyMessier-Dowty

SpiritSpirit

Boeing - CharlestonBoeing - Charleston

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Systems Suppliers

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A Different Business Model

Fewer risk-sharing supplier/partners

Greater integration responsibility

Detailed design responsibility

Greater standardization

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A Global Structural Test Program

Combined Pressure and Mechanical Tests

Fuel Seal Box Testing

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Static and Fatigue Testing

Ultimate Static Test

Fatigue Test

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Lower Skin LM Machined in the Kobe Shipyards

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Production Tooling for Fuselage Barrels

Boeing Aft Sec. 47/48

KHI Sec. 43

Boeing Sec. 48 Tailcone

Spirit Sec. 41

Alenia Sec. 46

Alenia Sec. 44

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Autoclaves

KHI SpiritSpirit Alenia

Vought

FHI MHI

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Facilities

FHI – Handa Plant

Boeing Charleston site

Alenia Grottaglie Facility

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Joined Section 43-46

Charleston, SCto Everett, WA

JoinedSection47-48

Charleston, SC to Everett, WA

Section 41Wichita, KS to Everett, WA

Section 46Grottaglie, Italy

to Charleston, SC

Section 44Grottaglie, Italy to

Charleston, SC

Horizontal StabilizerFoggia, Italy

to Charleston, SC

WingNagoya, Japanto Everett, WA

Section 43Nagoya, Japan

to Charleston, SC

Section 11/45Nagoya, Japan

to Charleston, SC

Dreamlifter Route Structure

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Worldwide operations, less work in process

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Dreamlifter Progress

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Final Assembly: Wing-to-Body Join

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Existing Boeing Charleston site

Second 787 Production line(artist rendering)

South Carolina enhances delivery rate capability

Scheduled to be operational in Summer 2011 Transitional surge line in Everett until Charleston site is completed Establishing dual sourcing to assure supply chain continuity

New final assembly

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Increased visibility of time sensitive issues ‐ 24/7 response

Increased visibility across the supply chain ‐ greater situational awareness

Problem Resolution

Ready To Ship

Situational Awareness

What the PIC does 

Production Integration Center

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Leading Globally

Technical competence

Systems perspective

Cultural awareness

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All About PeopleSelecting Our Global Partners

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Working Across the Globe

The GCC (Global Collaboration Center)

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The Joint Development Phase

Bastille Day Celebration

Golden Week

Korean Potluck

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Initial Technology Development in Seattle

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Sealing Up Co-Cured Technology

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Joint Spar Development

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Collaborating with Colleagues Around the World

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FHI 787 Handa Plant Celebration

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Building our Global Enterprise

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Principal Investigators

Procurement Agents

IPT Leaders

Facilitator/Mentors

CulturalFluency

Cultural Knowledge

Cultural Familiarity

US-based employees with infrequent interactions with team members from other cultures

Personnel with frequent, on-going interaction with team members from other cultures

Consultants

7E7 Tiered Awareness Training Approach

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Thank You