Boeing today confirms that the 737 programme faces a new challenge to return to full rate production. Thousands of small pieces of structural hardware must be replaced because of a lack of corrosive coating.The airframer says the components, known as nutplates, do not present "an immediate safety of flight issue."
The problem impacts "thousands" of nutplates in each 737 fuselage. The company adds that about 30% will require replacement, a number that runs about 3,000 to 4,000 nutplates per fuselage according to a program source, though the number varies depending on the model of 737.
Boeing is currently ramping up 737 production to its normal rate of about one per day, following the 57-day strike by the International Association of Machinists and Aerospace Workers (IAM). The nutplate quality issue, however, means assembly workers must scramble to replace the parts before each aircraft now on Boeing property can be delivered.Boeing emphasizes that no 737 will be delivered unless it meets proper conformity standards. Boeing declined to specify what impact the nutplate replacement would have on the pace of production and deliveries.
Boeing says it is devoting significant resources to solving this problem quickly.
Spirit AeroSystems is responsible for development of the 737 fuselage at its Wichita, Kansas facility. Once completed, the green 737 fuselage is shipped by rail to Renton, Washington, for final assembly.
Once completed, aircraft are flown to Boeing Field near downtown Seattle for delivery to customers.
Boeing says that one of three of Spirit's nutplate suppliers had been delivering parts lacking anti-corrosion material, adding that a root-cause analysis will be undertaken in conjunction with Spirit to prevent the problem from recurring.
Spirit was unavailable for comment.
Boeing adds that all non-conforming nutplates that have yet to be installed at Spirit have been returned to the supplier.
Staff from Spirit have been dispatched to the Seattle area to help identify and fix fuselage sections that are not yet in the final assembly phase.
However, the problem is not limited to only those aircraft waiting to be assembled and delivered.
According to Boeing, 737s delivered to customers since August 2007 contained non-conforming nutplates. Boeing's delivery website says that 394 737s were delivered between August 2007 and October 2008.
The company is working with the FAA to address the in-service fleet. Boeing says that only areas exposed to moisture could potentially present problems in the long-term by corroding prematurely.
737-800 Assembly Video after the jump
Photo Credit: FlightBlogger
on November 13, 2008 7:59 AM | Reply
"Boeing says that only areas exposed to moisture could potentially present problems in the long-term by corroding prematurely."
So just how fast will these things corrode in the cool moist atmosphere that prevails in North West England? Ryanair's shiny new 737s fly over my house every day!
on November 13, 2008 11:54 AM | Reply
How could this happen again?? Were both quality and incoming goods inspectors sleeping?
I think that FAA should have a deep look on Boeing before the planes start falling out of the sky!
on November 13, 2008 8:39 PM | Reply
The nut plate issue is a part of the problems that will occur when outsourcing is part of the process. Inspections are done by the suppliers. Continued outsourcing will result in reduced quality of Boeing airplanes and eventually will damage their reputation. The CEO and board of directors will not be around to be held responsible when that happens because they will retire as wealthy individuals. Hope they have already bought their BBJ.
on November 16, 2008 12:22 AM | Reply
Following on Ed--It's really sad to see a prime American contractor reducing itself into a branding operation. I feel for the proud Boeing workers taking management's credibility hit and having to bail them out simultaneously. The negotiations must have been 'interesting'.
on November 16, 2008 12:48 AM | Reply
An additional follow on--who needs corporate espionage when the primes will give it away for sales, 'risk sharing', and theoretically lower delivered cost? This die cast by Boeing and Airbus (an assembly line in China for 4 planes a month?) will rebound terribly when China, India, and Japan, individually or in concert, develop and market their own 200 seat aircraft. A diminished Boeing brand will ease their path.
on November 16, 2008 4:26 AM | Reply
Remember Aloha Air flight 243!
The airframer says the components, known as nutplates, do not present "an immediate safety of flight issue."
No worries, then.
on December 12, 2008 4:51 AM | Reply
The ISO 9001 standard requires that a company develops and implements a basic quality management system, using the specific elements to ensure the company is capable of maintaining uniformity of its processes and, as a result, provides its customers with a consistent quality of products and services. ISO 9001:2000 comprises a series of standards outlining the requirements for quality management systems.