Click here to load reader

Boeing 787 Lessons Learnt

  • View
    168

  • Download
    4

Embed Size (px)

Text of Boeing 787 Lessons Learnt

October 2008

Presented by

Burkhard DOMKEHead of Engineering Intelligence Future Projects Office

Boeing 787 Lessons Learnt October 2008787 Lessons Learnt 2.0 20. October 2008 46 pages

TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2

AcknowledgementsFelix Lutsch, EIXG 787 Overall Aircraft Design, Weight, and Performance Analysis Iain Morgan, EIXV Long Range Sector Manager Peter Brink, EIXDI Detailed Analysis of 787 Structural Design, Manufacturing and Supplier Facilities Matthias Heimerl, YDI Supplier Business Intelligence Louis Nobre and Norio Yamanouchi, Airbus Japan Local Supplier Information Joanne Potter, PAWT1 / TWA Production Status & Ramp-up Issues

AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2

October 2008

Page 2

Overview Design Issues Weight Issues Engine Issues Certification Issues Production Issues Travelled Work Lay-up Rates Ramp Up Schedule Issues AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2

October 2008

Page 3

Design Issues - Summary Wing Center wing box static test failure Lightning strike protection Wiring definition

Fuselage Lightning strike protection Body join across window concept Mid body section join assembly AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

Aft body join assembly (including pressure bulkhead) Aft body and APU tail cone join MLG doors Pi-Box seat rails Hybrid sine-wave floor beams Single-piece frames

TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2

October 2008

Page 4

Design Issues - Summary HTP Center splice Additional spar Pylon Common pylon/nacelle Systems Power Electronics Cooling Brake control software Generators AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

Cabin Wireless IFE 16g seats Engines Fuel burn

TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2

October 2008

Page 5

Design Issues - WingCenter Wing Box (Section 11) The center wing box failed assembly-level static testing. The Issue was attributed to an FEM calculation error and classified as minor by Boeing Boeing planned to implement a temporary fix for LN1 to LN6 and a permanent solution from LN7 onwards Japanese supplier sources deemed this a major issue with significant impact on production

Outboard Wing (Section 12) Issues with wiring definition and design changes due to lightning strike protection Engineering changes were interrupted by the center wing box issue AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

In April, Boeing announced a revised wing design incorporating significant weight savings from LN20* onwards A customer presentation indicates a post-EIS increase in MTOW from 219 to 227 tonnes from LN20 onwards. A Boeing source dated August 2008 advertised a revised airframe supporting this weight increase. This includes strengthening of the outboard wing, the center wing box, the wing leading edges, the MLG wheel well, and the center fuselage as well as enhancing manoeuvre load alleviation. Delivery of LN21 in 4Q 2009 leaves a tight schedule to achieve such a redesign and its incorporation into early production.TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 October 2008 Page 6

Design Issues Wing Fasteners / Lightning Strike Fastener design changed to tapered sleeve bolt type late in design to prevent edge glow within fuel tanks (1) At the time, production lead-time of fasteners was ~60 weeks This lead to a limited availability of tailored-length fasteners Stacks of washers conceived as a workaround created problems with incorrect assembly (2) Solution infringes a BAE patent owned by Airbus

AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

1 2TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 October 2008 Page 7

Design Issues - Fuselage

2

3Body join S41/S43 and S46/S47 Initial concept ran the join right across the window (1) Concept altered after barrel mating demonstration Windows eliminated on LN1 (2) AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

No mitigation observed, not even on later models like the 787-10 (3) Affected passengers may not be happy!

1TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 October 2008 Page 8

Overview Design Issues Weight Issues Engine Issues Certification Issues Production Issues Travelled Work Lay-up Rates Ramp Up Schedule Issues AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2

October 2008

Page 9

787-8 Weight Evolution Charts787_Evol_0908_EIXUG_PR0812577_v2Pax 260 Seat count 250 SPP Range 8000

787-8 Positioning Evolution

Range [nm ] 8500

AI LR standard changed 3cl to 2cl ADS.K Ad.240

7500

ADS.G

ADS.E

ADS.H

ADS.C

ADS.A

ADS.B

ADS.F

ADS.J

ADS.K

7000

230

ADS.(K++)

ADS.D

6500

6000 220 Dez 02 Mrz 03 Jun 03 Sep 03 Dez 03 Mrz 04 Jun 04 Sep 04 Dez 04 Mrz 05 Jun 05 Sep 05 Dez 05 Mrz 06 Jun 06 Sep 06 Dez 06 Mrz 07 Jun 07 Sep 07 Dez 07 Mrz 08 Jun 08 Sep 08

Program launch

MZFW [t] 165 AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

787-8 Design Weights Evolution

MTOW[t] 230 225 220 215 210 205

MZFW 160 MTOW

155

150

145 200 Dez 02 Mrz 03 Jun 03 Sep 03 Dez 03 Mrz 04 Jun 04 Sep 04 Dez 04 Mrz 05 Jun 05 Sep 05 Dez 05 Mrz 06 Jun 06 Sep 06 Dez 06 Mrz 07 Jun 07 Sep 07 Dez 07 Mrz 08 Jun 08 Sep 08

Firm ConfigurationSeptember 2005 Firm Configuration (3 month delay)

TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2

ATO

October 2008

Page 10

787-8 Weight Evolution Charts787_Evol_0908_EIXUG_PR0812577_v2MWE [t] 102 98.9 98 95.4 94 90 ADS A MWE [t] 8

787-8 AI MWE Evolution101.2 100.0 98.9 96.5 96.5

95.4

94.6

94.4

95.5

92.8

ADS B

ADS C

ADS D

ADS E

ADS F

ADS G

ADS H

ADS J

ADS K

ADS K Ad.

Post EIS

787-8 AI MWE vs ADS Rev.F (firm configuration)6

5.7 4.5 3.4 3.4

AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

4 2

1.0 -0.1 -0.1 -0.9 -1.1 Ref.ADS F ADS G

1.0

0

-2.6-2 -4 ADS A ADS B ADS C ADS D ADS E ADS H ADS J ADS K ADS K Ad. Post EIS

September 2005 Firm ConfigurationTI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 October 2008 Page 11

Weight Evolution tables787_Evol_0908_EIXUG_PR0812577_v2

787-8Design. 7E7-300 7E7 base 7E7-8 Key Date Jan 03 Jul 03 Nov 03 Mrz 04 Jun 04 Nov 04 Mrz 05 Okt 05 Mai 06 Aug 06 Dez 06 Jul 07 Apr 08 Aug 08 Status ADS A ADS B ADS C ADS D ADS E ADS F ADS G ADS H ADS J ADS K ADS K Ad. Post EIS Pax 245 228 223 221 221 251 255 252 252 248 248 248 248 248 Standard 3cl LR 3cl LR 3cl LR 3cl LR 3cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR MTOW 214.6 202.9 205.3 216.6 216.6 215.9 215.9 215.9 217.7 217.7 219.5 219.5 219.5 227.9 MZFW 153.8 147.4 149.7 154.2 154.2 154.2 154.2 154.2 154.2 154.2 156.5 156.5 156.5 161.0 MWE 96.1 89.7 92.8 95.4 95.4 94.6 94.4 95.5 96.5 96.5 98.9 98.9 100.0 101.2 DMWE 0.6 -5.7 -2.6 -0.1 -0.1 -0.9 -1.1 0.0 1.0 1.0 3.4 3.4 4.5 5.7 Range 7490 7500 7650 8420 8420 6884 6723 6547 6680 6750 6590 6490 6370 6890 Comments initial configuration information extensive compsites, more electric (no bleed), sakurai hili, cap.reduced span increase, longer nose/tail, reduced LG-length, growth revised TE, conv. hili multifunct, revised tail, growth tracing skipped span inc., changed nose/tail/HTP/VTP, D3 derated, AI rules changed inc. fuse/cabin length, inc. VTP, revised wing ref area VTP increased, new aft galley arrangement untraceable MWE increase, recovery growth no changes untraceable MWE increase, partial recovery growth no weight changes, untraced performance reduction untraceable MWE increase growth

787-8

787-9 AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document.

Design. Key Date 7E7-400 Jan 03 7E7 stretch Jul 03 Nov 03 7E7-9 Mrz 04 Jun 04 Nov 04 Mrz 05 787-9 Okt 05 Mai 06 Aug 06 Dez 06 Jul 07 Apr 08

Status

ADS A ADS B ADS C ADS D ADS E ADS F ADS G ADS H ADS J ADS K ADS K Ad.

Pax 294 277 276 273 273 286 290 286 286 284 284 284 284

Standard 3cl LR 3cl LR 3cl LR 3cl LR 3cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR 2cl LR

MTOW 221.1 219.8 230.0 230.0 230.0 230.7 230.7 244.9 244.9 244.9 244.9 244.9 247.2

MZFW 171.0 163.8 167.8 167.8 167.8 169.6 170.6 174.2 176.9 176.9 179.2 179.2 181.4

MWE 98.5 93.8 98.5 98.5 98.5 98.8 99.3 102.9 103.9 103.9 106.4 106.4 108.4

DMWE -4.4 -9.1 -4.4 -4.4 -4.4 -4.1 -3.6 0.0 1.0 1.0 3.5 3.5 5.5

Range 6735 7500 7950 7970 7970 6727 6494 7261 7170 7200 6940 6870 6810

Comments initial configuration information extensive compsites, more electric (no bleed), sakurai hili, cap.reduced span increase, longer nose/tail, reduced LG-length, growth revised TE, conv. hili multifunct, revised tail tracing skipped span increase, changed n

Search related