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

COPYRIGHT © 2010 THE BOEING COMPANY Coleman/Jenks to MIT (SDM) on October 21, 2010 | 2

Agenda

Program Overview and History

A Highly Integrated Global System

Leading Globally


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

2001 - 2002

2003


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


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


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


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


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

COPYRIGHT © 2010 THE BOEING COMPANY

Unprecedented Market Response

*

*

• As of 31 August, 2010* Leasing operator

847 orders from 55 customers


787 RolloutJuly 8, 2007


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


Video


Everett Final Assembly


Agenda

Program Overview and History

A Highly Integrated Global System

Leading in Complex Global Systems


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


Systems Suppliers


A Different Business Model

Fewer risk-sharing supplier/partners

Greater integration responsibility

Detailed design responsibility

Greater standardization


A Global Structural Test Program

Combined Pressure and Mechanical Tests

Fuel Seal Box Testing


Static and Fatigue Testing

Ultimate Static Test

Fatigue Test


Lower Skin LM Machined in the Kobe Shipyards


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


Autoclaves

KHI SpiritSpirit Alenia

Vought

FHI MHI


Facilities

FHI – Handa Plant

Boeing Charleston site

Alenia Grottaglie Facility


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

COPYRIGHT © 2010 THE BOEING COMPANY

Worldwide operations, less work in process


Dreamlifter Progress


Final Assembly: Wing-to-Body Join


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


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


Leading Globally

Technical competence

Systems perspective

Cultural awareness


All About PeopleSelecting Our Global Partners


Working Across the Globe

The GCC (Global Collaboration Center)


The Joint Development Phase

Bastille Day Celebration

Golden Week

Korean Potluck


Initial Technology Development in Seattle


Sealing Up Co-Cured Technology


Joint Spar Development


Collaborating with Colleagues Around the World


FHI 787 Handa Plant Celebration


Building our Global Enterprise


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


Thank You

Documents

Boeing 787 - Challenges of Complex Global Systems