October 2008 Presented by Burkhard DOMKE Head of Engineering Intelligence Future Projects Office Boeing 787 Lessons Learnt October 2008 787 Lessons Learnt 2.0 20. October 2008 46 pages TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 Production Issues - Summary o Parts Shortages o Fastener Shortage o Travelled Work o Conformity and Quality Assurance Issues o Configuration Control o Shop Floor Control o Late Definition o Engineering Changes o Production Ramp-up Issues (C) AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document. TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 October 2008 Page 19 Production Issues - Travelled Work o Parts shortages - Insufficient supply of frames, clips, brackets, and floor beams. Root cause are o NDI/QA cycle time not supporting production rate demand o Lack of qualified NDI/QA personnel and equipment at Tier-2 and -3 suppliers o Deferral of NDI testing from Tier-2 and -3 suppliers to Tier-1 partners to expedite preassembly o Further deferral of NDI and assembly work from Tier-1 to FAL to rush major assembly o Large number of defects detected at FAL level. Removal and replacement of defect parts incurring damage and repair o Repeated NDI/QA testing at FAL level due to all of the above (C) AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document. o Fastener shortages, primarily affecting but not limited to Mitsubishi. Root causes are o Late change to sleeved fastener design for lightning strike protection o Alcoa unable to meet demand in time o Unbalance in fastener inventory across supply chain o To tackle the parts shortages Boeing has now taken a consolidated approach to inventory management across the supply chain. TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 October 2008 Page 20 Production Issues - Travelled Work o Documentation o Production records on deferred work were found to be incomplete or lost in transfer resulting in a loss of configuration control o Assembly work was found to be completed incorrectly only after assemblies reached the FAL. Root causes are o Oversight not adequate for the high level of outsourcing in assembly and integration o Qualification of low-wage, trained-on-the-job workers that had no previous aerospace experience o Significant amount of change engineering work o Inadequate supplier capabilities in design, e.g. Vought had no engineering department when selected o Oversight not adequate for the high level of outsourcing in detailed design o Weight growth and subsequent weight saving changes o Producibility improvements o Late Definition o Boeing admitted responsibility for a shortfall in wiring shipments o Late specification indicated by supplier as root cause (C) AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document. TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 October 2008 Page 21 787 Body Section Overview Moveable Trailing Edge (HdH) Vertical Fin (Boeing-Fredrickson) Center Fuselage (Alenia) Forward Fuselage (Spirit) 41 46 48 47 Wing-to-Body Fairing (Boeing-Winnipeg) 44 43 Forward Fuselage (KHI) Center Wing Box (FHI) Main Landing Gear Wheel Well (KHI) Leading Edge (Spirit) Wing Box (MHI) 45 11 (C) AIRBUS DEUTSCHLAND GmbH. All rights reserved. Confidential and proprietary document. Horizontal Stabilizer (Alenia) Aft Fuselage (Vought) Fixed Trailing Edge (KHI) Wing Tips (KAL-ASD) TI - Boeing 787 Lessons Learnt - EIXDI - Ref. PR0813399 - Issue 2 October 2008 Page 42