The installation of the wing fix for the first 787 - ZA001 - is now complete, with program sources telling FlightBlogger that flight test schedules have readjusted to target late December for first flight just before Christmas.
Boeing declined to confirm the completion of the installation but says that "we are satisfied with the progress being made with the modifications and are on-track to fly before the end of the year."
As part of the Z18 program schedule, Boeing initially targeted late November for first flight, but the on going pace of engineering design, the availability of the machined fittings, and the installation of the wing fix has slid 787 first flight roughly a month.
The latest target holds 787 first flight within Boeing's latest revised target of flying by the close of 2009.
Sources also indicate that the wing fix is slated to undergo full-scale testing on the static airframe is currently slated for late-November. Once complete, Boeing engineers will study the results to validate the wing fix and clear ZA001 to begin its certification campaign.
Additionally, as a result of the completion, ZA001 restoration work is scheduled to begin today in Everett.
Restoration consists of a thorough cleaning, re-installation of systems and complete panel close out.
Once restoration is complete, what remains unknown is if ZA001 will stay in the paint hangar while ZY997 undergoes final validation or return to the flight line to re-start preparation for first flight.
on November 10, 2009 4:34 PM | Reply
I would venture to argue that whether ZA001 stays in the paint hangar after restoration or goes to the flight line is a strong indicator of Boeing's confidence in the fix. If they believe they fully understand the issue, the fix, and the downstream effects of both, they aren't going to waste any time getting ZA001 ready to fly.
on November 10, 2009 4:53 PM | Reply
Jon,
I remain puzzled that the announcements have always been that ZA001 wing fix is complete while information on ZY 997 plays some subordinate role and its "fix" was not indicated earlier.
The validation is needed from ZY997 and the static wing test. Why will it take several weeks now to effect that test. One would have thought that this was the pacing item.
Boeing must be very confident that this will work because you indicate that they will be closing up ZA001 and possibly moving it to the flight line for pre flight preparations...i.e.. taxi, etc.
I am optimistic for some intuitive reason and think this is being orchestrated for a Holiday flight...an auspicious end of the year followed several weeks later by the 747 first flight.
It certainly would be some good dramatic news following a very difficult year. Maybe they will even paint a Santa and a sled to make it more welcoming.
Thanks again for the update
on November 10, 2009 5:27 PM | Reply
Wow, or should I get excited yet. Testing is the pacing item at this point.
on November 10, 2009 5:34 PM | Reply
Trapperpk is right. ZY997 remains the pacing item.
on November 10, 2009 5:36 PM | Reply
Remember, Boeing had to split workforce to get both ap1 and the static ap finished at the same time. Also, the static ap needs time to be re-prepped for testing. I think the two fixes falling within a week or two of each other is perfectly acceptable, as neither relied on the other to complete thier work.
on November 10, 2009 5:51 PM | Reply
Say ... I was named Automobile Magazine's "2010 Man of the Year" today ... WOO-HOO!!!
on November 10, 2009 6:09 PM | Reply
Hmmm... If FF is about 6-7 weeks away, what else if anything needs to happen? You mentioned some prep work and I think boeing said they would have to go through some more testing. Time to pick up on that "road to first flight" series again.
Flying to Seattle to watch FF might be an interesting vacation. And I could use one.
on November 10, 2009 6:12 PM | Reply
jerry1t replying to Engineer #3
I really do not understand your response since I do know know what you meant by the ap 1 and the static ap finished at the same time. But it seems that this is acceptable to you so let it be.
You would think that there was plenty of time to have re-prepped the static wing rig unless new information has to be programmed into it because of the fix. In essence, while time was passing waiting the fix, everything that could have been done should have been done so time would not be wasted.
Anyway, you can see that there is some anticipation and anxiety about this milestone and we have one too many disappointments already so, if they wish to prepare at their own pace, so be it. Just get everything right this time an start the certification flight already!
on November 10, 2009 8:02 PM | Reply
Congratulations Allan on your accolade. You and the folks over at Ford have sure have done your home work and deserve to be recognized for your hard work. But may I ask you one question. Why are cars to un-field serviceable? Why do you have to take half the car apart to change a head light or change the air filter or change a spark plug? It would sure be great if you could make cars fun to work on again instead of a nightmare. If you can fix that I promise you the next car I buy will be a Ford.
Okay, back to the 787. Correct me if I am wrong, but once they get ZA001 buttoned back, I thought they were going to roll her back out to the flight line and repeat some of the gauntlet in order to make sure she is flight ready.
on November 10, 2009 8:21 PM | Reply
So the static test article is stuffed full of test fittings, cables, strain gages, etc. Its going to take more time as compared to LN1 to complete the fix while dealing with all the extra stuff in the way. Also, extra strain gages on the static test are likely being installed to closely monitor the fix. So the simple answer is yes, LN9997 paces first flight, but its nothing more then dealing with the complexity of the static test article as compared to LN1.
on November 10, 2009 8:24 PM | Reply
Does this mean that ZA002 is complete as well? Wasnt she "ahead" of ZA001 in progress of installing the fix?
on November 10, 2009 9:36 PM | Reply
Congratulation! You deserve it 100%. Against all odd, you have not only survived, but thrived. Same for Ford. Hope Ford will continue on its path of recovery and be a great company again.
Best wishes,
Michael Lam
on November 10, 2009 9:51 PM | Reply
I will add to 787Supplier's reply for the benefit of Jerry1t that the static ground testing is a very complicated and thorough ordeal. They don't simply hook the plane up and do one big, five minute test. They will have many of the same inspections to do as for ZA001. Following that, they will conduct the test in stages, probably not more than one test per day, each with gradually increasing loads. Each time they'll have to analyze the data to see if it matches their expectations, inspect the airframe for any signs of damage, and discuss the results before proceeding.
When you only have one test article, and mistakes can take weeks or even months to correct, you take the time to do things right the first time. I have little doubt ZY997's fix is also installed and being prepared for testing. Having only unofficial sources can easily explain why Jon got news about ZA001, but not ZY997.
I will nitpick that while ZY997 no doubt has more test instrumentation, don't forget that ZA001 will also have quite a bit of instrumentation onboard to set up.
Couple that with the fact that Boeing has been burned before by bragging about progress in one area only to have a delay in another area, and I don't expect any official word at all from Boeing until ZY997 has been loaded to 150% and deemed acceptable.
on November 10, 2009 11:01 PM | Reply
Hmmm, 787's first flight just before Christmas. That conflicts with my vacation plan. Should I cancel my vacation to go see 787 fly for the first time?
on November 11, 2009 2:17 AM | Reply
Time for the Grinch to make an appearance.
All of these fixes, when they were announced back in September, were supposed to be finished by early October. We are now in early to mid
November and they are only now getting the rework on the first aircraft and the static rig finished.
Seems to me as if Boeing still does not have a grip on estimating or planning.
Sorry to rain on many of your parades, but many of you might thank me for this dose of reality when the next delay is announced.
Regards,
John
on November 11, 2009 6:49 AM | Reply
I think Boeing finaly realized, that they have a big difference between metall and compound. Working with metall the statical test gives a good conclusion for all over the live. If compound withstands the statical test, we have only a little conclusion. The main conclusion is withstanding the dynamical test! Remember there was delamination. This also happens with good statical data, but after long therm dynamical load.
on November 11, 2009 8:38 AM | Reply
According to Uresh at All Things 787, 1st flight of ZA001 is scheduled on 22nd December, 09.
http://nyc787.blogspot.com/2009/11/first-flights.html
on November 11, 2009 9:14 AM | Reply
Not a very reliable blog, they've been throwing around many different dates since July
on November 11, 2009 9:46 AM | Reply
Bah humbug. When it flies, it flies.
on November 11, 2009 9:54 AM | Reply
Iamlucky13 and Andy X indicate the complexity and thoroughness needed to get through the static wing test and Grinch JayPee brings some skepticism because of some slippage in the indicated schedule.
I just recall that when Boeing said it would fly before the end of the year it was said by some commentators that they left themselves some slack so as to deal with any unexpected items as well as not rush the process.
Sounds like they have used some slack time.Not a calamity.
It appears that the static wing test is the key here and we will all have to be patient hoping the fix makes it through a slow and steady climb above 150%
on November 11, 2009 11:32 AM | Reply
Concerning ZY997 and the "fix" installation time line - does not Boeing first - or concurrently - have to repair the (unexpected) damage at the side of body joint area? If so is not the static test confirmation of the "fix" also confirmation of the repair?
I have yet to read anything about the repair aspect of ZY997.
on November 11, 2009 4:06 PM | Reply
"ssems like they have used some slack time"
The design of the fix was targeted for completion end of August. It was completed 26 October. Eight weeks of slack time.
on November 11, 2009 4:56 PM | Reply
787 first flight schedule revealed - December 32nd is the magic day !
(A fine aerospace tradition started with the Lear FAN)
on November 11, 2009 6:56 PM | Reply
"Concerning ZY997 and the "fix" installation time line - does not Boeing first - or concurrently - have to repair the (unexpected) damage at the side of body joint area? If so is not the static test confirmation of the "fix" also confirmation of the repair?"
Spot-on question. However, we know neither the extent of the damage or what was required to repair it. Presumably that repair work was on-going while the fix was being designed and run through computer simulations, or was done concurrently with the fix. I seem to remember some commentary to the effect that lessons learned on ZY997 would help with the fix installation on ZA001 et al.
One could speculate that we haven't heard anything because the damage hasn't been fixed yet.
However, given the decision not to fly before the static test gives acceptable results, it only makes sense that ZY997 would be given the highest priority for installation of the fix and any related repairs. That leads me to the think instead the crew working on ZY997 is simply more tight-lipped than the crew working on ZA001.
on November 11, 2009 7:57 PM | Reply
Anybody able to comment on the brake temperature situation - whether and how it has been addressed during the side of body fix?
on November 11, 2009 8:01 PM | Reply
Sorry to say this Boeing - but dont put public opinion before sound engineering judgement - first test - then assess!
Remenber Challenger and Columbia!!
This ship should be put back in the test rig for major wing deflection tests and then stress analysis undertaken and then assessed as part of a total quality management protocol.
Not thrown back out on the flightline for some poor test pilot to find the fix didnt quite work.
The media should back off as well!! this is an aircraft and a highly sophisticated machine and takes time to resolve issues - not a defective automobile - I'm sure you can read between the lines!?
on November 11, 2009 11:14 PM | Reply
Allan, congratulations from the Signature Flight Support Door man. I met you and your son back when Qantas returned to SFO in 2006. Thanks for all the great 777 gifts; I will cherish them as well as your hand written letter for the rest of my life.
Allan Mulally: "The Father or the Triple Seven"
Chris Coakley
exec.flightservice@yahoo.com
on November 11, 2009 11:29 PM | Reply
Alan, I'm sure you'll turn Ford into the great company it always has been; just like you did for Boeing. You will probably get the man of the Century with your positive attitude which is so contageous. You are are role model for the country, an inspiration to all.
Thaks again for all the cool Boeing 777 stuff.
Chris Coakley
owner/operator
Executive Flight Service
exec.flightservice@yahoo.com
on November 11, 2009 11:49 PM | Reply
The problem with the 787 is that it does not have Alan's enthusiasm behind it. Soon Ford will be on top and Alan then will take on the world.
Good show!
Chris Coakley
on November 11, 2009 11:52 PM | Reply
The problem with the 787 is that it does not have Alan's enthusiasm behind it. Soon Ford will be on top and Alan then will take on the world.
Good show!
Chris Coakley
on November 12, 2009 1:05 PM | Reply
Um... Chris? You do realize that's not the REAL Alan, correct? It's some smartazz spoofing his name. He's little better than a spammer.
on November 12, 2009 2:51 PM | Reply
If you want to evaluate a test like this you should take your time. Time for studying the loggings, x-ray, ultrasonic measurements, cross-sections etc. And most important you should take the time to discuss and review the results.
The last static test was november 2008. Remember how long it took before the company realized that they did have a problem and needed a fix? If I'm correct it was somewere in june that they removed the "milestone passed - static wing test" from their site.
If I read these bold statements that this time they are going to do the evaluation in two weeks, I get the jitters. Pushing engineers is one thing, rushing them is seldom a good idea.
To ensure that the test is properly done and evaluated perhaps the following items should be addded to first flight.
1) that they actually stress the plane to >100% wingload during flight.
2) that all marketeers and higher management involved in the FF decision will be included as passengers.
My guess is that FF will then not be before the end of Q1 2010. But it will be safe.
on November 12, 2009 3:44 PM | Reply
This sure makes me confident that Boeing has its supply chain problems under control:
South Carolina Boeing Quality Inspector: $12 an hour.
http://preview.tinyurl.com/yda7786
on November 13, 2009 9:05 AM | Reply
[b]What you pay is what you get...[/b]
(Olde Germany Saying)
Best regards from Germany
Andreas
(Make more than US-$ 12 per hour)