Special Report: Dreamliner Outsourcing; What Went Wrong?

7/28/2019 Special Report: Dreamliner Outsourcing; What Went Wrong?

1/11

a wing and a prayer:

outsourcing at boeing

REUTERS/AnThony BolAnT

Te Dremer tree er ed cede d mve ver det.Wt wet wr? Crtc pt t trc.

By KylE PETERSon

EVERETT, WashingTon, Jan 20

On a blusTERy anD DRizzlyDecemer ter te Pcc

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Te prked pe re 787-8 Dremer,

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mk.bt t td.Te prrm tt prdced tee

ed 787 er tree ered cede d, me etmte,t et ever dr ver det.Dremer ft tet were ted nvemer ter eectrc re rd tet pe. Te tet remed Decemer,

d te cmp ter ced eter de r te dever cede. Teew ETa metme t mmer.

at 45 me (72 km) w tsette, memer be wrk rcetered t r mt demeet, d prt d cce t

met te emc t pe-mktrte te te Dremer repreet

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ited drw prmr rm ttrdt p rcrt eeermecc d rer tt r

january 2011


2/11

dREAmlinER jAnUARy 201

eert deep te Pet sd rerd sette, be ed terttem pper d eeer rm teuted stte, Jp, it, atr, Frced eewere, w mke cmpet ttbe wrker te uted stte ptteter.

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er, mt wrk ctr et.Wm, we ter wrked t be

r mre t tree decde, jt e m te cmp w me terepeted Dremer de pteredeeer trte d cmpe ppc t 50 prter.

be te ckweded tt tetem eed twek, d te cmpprme t r mre te de wrkck -e r te pcm 787-9 mde.bt be deed t rece tdeprter, ter wrk d vetmet

mde te Dremer pe.it tre tt pper vvemet

te devepmet d de te 787 ct, te cmp d emedrepe t Reter qet. sppereped devep d dertdtece d pt r te rpe we wet tr te er pe cceptdevepmet. spper ve prvdedmre ter w devepmet, de dmctr d.

Wtever te dvte, betrc ememtc crprteprctce tt ve et re ck u.s. dtr vere d t ter tte,ttered cmmte d vted te u.s.

je rte t er 10 percet, ecmt.

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it w ke te m, d Wm,we we, sr, d tree cdre jedm r te d prt. C trceMm? C trce Dd?

ShRinKinG WoRKFoRCES

boEing is ThE WoRlDs ecd-retcmmerc pe-mker ter t Erperv ar. Fded 1916 sette Wm be, te cmp ered $68.3 revee 2009, pt etwee t

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at te tme te sept. 11, 2001 ttc new yrk d Wt D.C., bett wrkrce w t 199,000. deee d cmmerc t ed 20,00

j etwee Jr 2002 d J2003 ter te 9/11 ttck prked tedece r trve d rcrt rder.

Mrd ter u.s. mctrer cj dr tt ecmc dwtr, m te ever reed ter rmt eve.

U.S. manufacturing jobs, 1950-2010

* Production and non-supervisory jobsSource: U.S. Bureau of Labor Statistics

Reuters graphic/Stephen Culp

Employed in U.S. manufacturing millions* Unemployment rate percent

Over the past 60 years, U.S. unemployment has mirrored manufacturing sectors ups and downs.

0

2

4

6

8

10

12

14

8

9

10

11

12

13

14

15

2010200019901980197019601950

A lot of Westerneurope WAs still

reeling After WorldWAr tWo, And so Wedidnt hAve the sAmekind of competition

When it cAme tomAnufActuring in

the 50.

BoEinG FAmily:aeospce Mchiist Idstil Distict

Lodge 751 io membe jmes Willims speks t hisios oce i Settle, Wshigto o Decembe 8, 2010.

REUTERS/AnThony BolAnTE
http://link.reuters.com/heq72q


3/11


Wt ve ee ct dece mctr empmet tt ddt jttrt 20 er , d stepe brr,er ecmt t Wec Ct. adt ccetted dr dwtr, were ee te teepet dece mctrempmet we tere rece.

at t merc pek, 1978, te u.s.

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sce te 1970, empmet mctr e mre t 30percet te uted stte, cmpred wtt 60 percet brt, d t 20

percet Jp.Te cme te 2008/2009 ecmc dwtr, wc wped t er8 m u.s. j. at 2 m tewere mctr. Ecmt eevett m tee pt re e rd, rc e-cr wrker t ercr empmet eewere -- te t werwe.

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noT So SimPlE

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ce prmt wtt te dtrct

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Drve tr d ptc ece

All EnGinES Go:a rolls-roce egie bilt o the Boeig 787 Demlie ets sit o displ t the Fte o Flight avitio

Cete t Pie Field i Eveett, Wshigto o Decembe 8, 2010. REUTERS/AnThony BolAnTE


4/11


te 40-er-d pe-mker w rcedrm te tet t crete tem wcpe re t rm re ect mde

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rrme t tde pper. be tprced 65 percet te 787 rrme,wc cmpre t te 777.

bece te a350 w t e veere 2013 -- ret prev dterver prdct trte, ccrd t t crtc-- te EaDs dr c rd tt ck d er rm be percevedmtke te 787.

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oe te t dt wt ttrce r cre cmpetece,d Kre Krek, t eder temctr prctce t RsM Mcgdre, t d ct rm. it te t ttve r rt r ve dded.

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ThE PiVoTAl momEnT

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mrket re.be $16.3 prce

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sme crtc vew te merer te pt wc bCa e t vr crprctre tt pred er-term prt v-term eeer dmce. bckte er 2000 tere w eectve tr be , d Rcrd avce predet t vt ctc Te

grp.he d ter e t stecp

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ard t tme, be mved crprte edqrter t Cc t85 er sette. lr cmpte deprtre drve wede etweeectve d sette-re rk-d-bt te crprt cted eed t

Boeing and its Dreamliner

Source: Thomson Reuters 18/01/1

Boeing stock price $ S&P aerospace index

Jun 03: Boeing dubs its new, carbon composite airplane Dreamliner

Oct 07

1st delay:Productionproblems

Jan 08

2nd delay:Supplierproblemsand slowprogress

Apr 08

3rd delay:Supplierproblems

Dec 08

4th delay:Workersstrike andsupplierproblems

Jun 09

5th delay:Side-panelissue

Dec 09

Dreamlinertakes itsfirst testflight onDec. 15

Nov 10

Emergencylanding of 787test flight afterelectrical fire;Boeing later

halts test fligh

Aug 10

6th delay:Engine delay;first deliveryset for firstquarter

next year

100

200

300

400

500

600

20

40

60

80

100

120

JDNOSAJJMAMFJDNOSAJJMAMFJDNOSAJJMAMFJDNO

Reuters graphic/Stephen Culp

2007 2008 2009 2010 11

Jan 11

7th delay: Boeing says it will deliver thefirst Dreamliner in the third quarter of 2011

As We reduce these opportunities to leArn hoW to do these jobs,the boeing compAny becomes less cApAble to do the job.

TRiBAl KnoWlEdGE:Societ o Poessiol Egieeig

Emploees i aeospce (SPEEa), Itetiol Fedetio

o Poessiol d Techicl Egiees (IFPTE) Locl 2001

io Exective Bod Diecto Tom McCt speks t the

ios oce i Settle, Wshigto o Decembe 8, 2010.



5/11


er W street, Wt D.C. d

ctmer.bCa edqrter remed sette,t ttet ed te et prject.Tere were te ec cmmerc wce decde veted ver ev tecmp tre cret ew jet. adte tere were te ewcmer, ad.

Eectve, t w dmted t teMcDe D pepe w were ttemre ccered wt reder retd perp eve ter w wet, edded. ad te te dd t wt tmke vetmet.

be prev ttve, te 777, drecet etered ervce, d t w tme rbe t et t wrk t et ew mde.Repd t re demd r retere ecec, be e devepte de tt 2003 wd e dedDremer.

Te cr-cmpte trctre wd eter t mm pe cmpree d wd cme 20 percet e e.Te ccept w cred ppr mc-trpped re tt were t reerm drp trve demd ter 9/11.

bt we t cme tme t d te 787,be tred w rm t te eeer d mecc t emrce cmpe we pper. Fr te rt tme t tr, be wd trce te wde d mctr.

Tt, i tk te mrt pepe tere kew,w cred rk w d t, t tw te w te cd mve rwrd,a d. it w kd Ftr, i tk, tt a M mde. hedd wt e d t d t c te prrmve te tremed dvert e w

c.Fr t prt, be mt tt t ever

ded t tdrd r de deeer.

be ed te de ert, vereete prcee d t, d d treve d r prter t te ettdrd perrmce et dqt, te cmp d. it mprtt rbe t ret crtc k r eeerd d trctre c w d

cmpte trctre, be d.Te cmp d ped t mke rt

tet ft te Dremer rd teat 2007 d rt dever M 2008.bt tt tret e t p 2007 webe ptped te rt tet ft de t rte t d ft ctr twre.

Mre de wed prdctprem mted. i 2008, te cmp

med ter de 58-d trke be em wrker ver ctrctterm.

Te et er, be t prt e t tw t pper t epre ctr t Dremer prdct.it pd $580 m r te st Crpert Vt arcrt idtre, tecmp tt wrked te 787 t eeect.

be ter prced ae nrtamerc g aertc llC,

te st Cr ee emct r te 787. be dd t dcc term tt de. b tk aet te werp eqt, t tde te tt Cret, be d ttemet t te tme.

Te Dremer mde t rt f Dec. 15, 2009. bt e t er tte cmp ptped dever -- t

tme t er 2011 -- ece de tvt R-Rce ee eedr te pe ft tet.

i octer 2010, be d t wd tpper t t devere ect t 787 Dremer r tw week ec de t ae, t it deed erpce cmp Fmeccc spae mke te rt ter r tt te 787.

o nv. 9, te Dremer ced

bAck in the eArly2000s there WAs

effectively A bAttlefor boeings soul.

FEATURES

BOEING 787 DREAMLINER

Aircraft uses lightweight composites instead of aluminium(some 50% of the primary structure versus 12% for the lastall-new Boeing, the 777)

20% more fuel ecient than similarly sized planes

Fuselage is wovenout of composite inlarge barrels, savingtens of thousands of parts

Higher humidity inthe cabin, promisinga more comforableying experience

SEATING

RANGE

CONFIGURATION

CROSS SECTION

WING SPAN

LENGTH

HEIGHT

CRUISE SPEED

MAX. TAKEOFF

CARGO VOLUME

210 - 250

14,200 - 15,200 km

Twin aisle

574 cm

60 m

57 m

17 m

Mach 0.85 (920kmh)

227,930 kg

4,400 cubic feet

250 - 290

14,800 - 15,750 km

Twin aisle

574 cm

60 m

63 m

17 m

Mach 0.85 (920kmh)

247,208 kg

5,400 cubic feet

787-8 787-9

Price range$185.2 mln to

$218.1 mln

Net orders

847, as ofJan 19

Source: Boeing


6/11


edred ew ccp we re 787tet ft rced emerec d lred, Te.

be ted te tet ft prrm tdeterme te ce te re, wc t terttrted t re der eectrceqpmet cet. Te cmp remed787 ft tet te Decemer, td ted term ver pdtedpwer dtrt tem twre dcdcted rr et revew.

Te eectrc tem d pwer pe r

te 787 re t te hmt sdtrdt uted Tece Crp, mjrbe pper repe r ever kecmpet te 787 eectrc tem.

o nv. 30, Jm a, w tk ver bCa ce 2009, crmed t Reter ttbe wd de dever t t 787 cctmer a npp arw. Te, erert week, be ced tt t dmved rt dever t te trd qrter 2011 rm te rt qrter. Tt t et dte eect W street ccer

t eve er de.

ConTRiTion And dAmAGE ConTRol

noWaDays, boEing is qck ckwede te rck rd te Drem trveed r. i peec t te WC new yrk nv. 11 -- jt tw dter te eectrc re tt rded t787 tet feet -- be CEo Jm Mcnerppered cteed.

i retrpect, r 787 me p m ee ver mt, crprt tm rt t ce -- te ppct ew tece, revtr ded-d prcee, d creed rc eeer d mctrctet, e d.

bt e reterted te cmp te Dremer. We we cer tm te eect, we rem tedcdet te vtve cevemet te rpe d te eet t w r r ctmer, e d

be eectve deced t tervewed r t tr, t te cmpreped t wrtte qet mtted Reter. Te rc dec mde te 787 re tr evt te wde t be Cmmerc ver te erte cmp d. Weve d te ptt r te mt prt, we re ted wte eer drect. hwever, tere reew t we wd ce, d ve e mke ce te 787 ver te er

hARd WoRK And hEARTBREAK

baCK in sEaTTlE, wrker tke tte cm te wrd ter eder Mcnerete etme ed gE arcrt EeMcnere cme t be 2005 t tere CEo t 3M C, cmertt prdce te td dverprdct ke sctc tpe, medc md ptc m ed t rte ft creTV d cmpter.

a rp be empee, mtewrd te itert act Mct (iaM) , t dw w

PiloTS ViEW:aict fight iomtio is show o heds-p displ i the Boeig 787 Demlie Egieeig fight deck

simlto dig medi to o Boeig Co. egieeig lbs i Settle, Wshigto, M 22, 2007. REUTERS/RoBERT SoRBo

in retrospect,our 787 gAme plAn

mAy hAve beenoverly Ambitious,

incorporAting too

mAny firsts All Atonce.


7/11


Reter Decemer t decre ter weperece bCa prject, cd te787.

De swk, 47, rcrt mtecetecc te 787 prrm, w dprev wrked te 777, d i c t t d d r prcee dfw.

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vedred t, swk d.he reced tme te 787 prrm

we e r t prtcr wer t twt crew te pe. he d e d t t pper wrk t rder e werd wted e d t receve t rm tetde pper.

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prce dw.Tt emet red J

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ect teter. he d be p f te Dremer prt t sette r eem t wrked t.

o te 87, te de w be w t w tt. Tt t tw t cme kt -- te prt,

STill ConFidEnT:Boeig Chie Exective Oce jim Mcnee gestes to the medi s he stds i ot o the Boeig 787 Demlie ict t Fboogh ipot i Fboogh, sothe

Egld jl 18, 2010. REUTERS/KiERAn dohERTy


8/11


te teer, evert eeded t dt e prtcr j, Redrp d.

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he d trc ce te 1997 merer

-- d epec ce te Dremer -- mde e t be d te Pet sdre tre d m. Wrker wered v pe-mk w mtk eewere d te eve te tte.

We keep fd r wrk vere,d t ctt r wrk , Frmd. s we tk r j re w.Te tttde evere w erv.aw eede. streed t.

arcrt wrker er sette eredter w 2009 we, ter tte t keep 787 em Everett,

be eected st Cr te te t ecd 787 em pt. Tecmp m t rmp p 787 prdct t10 pe per mt 2013.

Te pt st Cr epected tcrete td ew j tt tted ke t e e drptve t bet t Everett cterprt, were r mjriaM trke te t tw decde ve ctbe t 200 d t prdct.Te mct st Cr, rt-t-wrk tte, vted t iaM repreett.

Tm Wrewk, dtrct predet teiaM t repreet be wrker te Pet sd re, d dwd trc ve tke t iaMmemerp, wc dw t t 25,000

td rm 42,000 1990.he trte pt wt rpc

depct wrk perrmed iaM memer mde be cmmerc pe.Prt te pe tt re mde iaMwrker re cred red. Te rpc r tee-e 737 mt red, cmpredwt te 787, wc etre tte red,m te vertc .

iaM memer d c vermeteder mted cmp ere wrke te 787 t etce be t mkete pe Wt. Te w terrpred t d t w tte wrk te cwd ct et.

n er dd te em t tew t we d t tt tercmmtmet w t em te rped tt w t, e d.

bt tree er de pek r te, ed. Te vt prterp w mett re rk d ct ct. Te ppte ppe, e d.

im de i td te 87,Wrewk d. We te ced

te were , we td tem t tpt: y , pt r e te pper t tere. yre t ctr r rpe. ad we ctr r rpe, tere t

c d. s wt ppeed? Teve ctr t.

WhAT WEnT RiGhT

onE KEy boEing pper d -tmprter t te cmp, u.s.-ed rcrcmpet pper Rckwe Cdree wt te etve emet r eder.

Tere v t tt et pretee d, d Jere stderk, vpredet d eer mer RckwC r trprt tem. bt i te wt: it re peme we tt te cce tt te be temre v te ft tet prrm.

Rckwe C mke cckpt eectrr te Dremer. Te cmp ctrct wt be ved t $3.5 ver te e te Dremer prrm.

stderk decre ceve ded mctr prce tt vvctt cmmct etwee beRckwe C, hewe itertgE d hmt sdtrd, w w rpe tem.

he d be ctcted pper t

eret te te 787 prrm d p detc r eeer t te vrcmpe. T ve tte mv cmpe rpe ec te creed ctt tt rpe, stderk d.

iterted rctectre evetw ecme te rm pe-mkstderk d, t cmprctrct prctce te ar a35it t cte t rce cmpe

We keep offloAdingour Work overseAs,And its cutting our

Work in hAlf.

ShAdES oF ThE FUTURE:Boeig egiee Geld Li-Kw demosttes high-tech electoicll shded widows tht will

be sed i the 787 Demlie iple dig medi to o Boeig Co. egieeig lbs i Settle, Wshigto, M 22, 2007.

REUTERS/RoBERT SoRBo

T ee pec reprt rm Je 2010 ter mjr erpce prject, te ara400M mtr trprter, cck ere:h://k.ee./28

a400M sPECial REPoRT
http://link.reuters.com/myc28mhttp://link.reuters.com/myc28mhttp://link.reuters.com/myc28m


9/11


vte, e d. it t cte t

rce cmpe t mke te vetmet reerc d devepmet t mke re ttwere wrk te tec r teet-eert rpe.

hoW Will ThiS PlAnE BE jUdGEd?

by noW, boEing has t 850 rder rte Dremer t k rm re drcrt e cmpe ver te wrd.it recrd mer rder r pe t devepmet.

avt epert rem tred tepe reprted e-ecec we teprme mt, qet, cmrterde r peer. Ter det w dp J we rde pe pttertered te permeter te Frrarw Ed t wtc te Dremerd ter t rt vere ft. avt de d tde be reqetc te 787 me-cer.

it t pe wt ver rd deer mrket, d Te grp a.it t tke tem tme t mkeme wt t. bt evet -- m t

wrk t -- tere t e td.Mewe, te mre t 50 ctmer

r te pe ve mt wted pc

crtcm be, depte te vc tdever de p wt ter -terfeet p. at eeve be

hEAVy liFTinG:Oe o the

Boeig comps Demlite

cgo ict sits o the

tmc t cto i Eveett,

Wshigto, apil 30, 2009.

REUTERS/RoBERT SoRBo

modEl AiRPlAnE:a Boeig emploee sits ext to tited widow o the Boeig 787 Demlie t Fboogh ipot i

Fboogh, sothe Egld jl 18, 2010. REUTERS/KiERAn dohERTy


10/11


pr red pd t dred m dr pet pmet

te dever.be t d wt t pet

te Dremer prrm r. bt epeeeve te pe t et ever dr ver det.

i te ed, te Dremer w e jd t et, ret d t t dev t m prme, d R grteectve drectr te sPEEa sette. Te re tet te 787 cme t rt er ervce, e d.

Te ret rte te Dremer wve t e er 100 percet t ppee c

cc re tt ct rd t pe reqet t ervce r repi t tr t tt t t d ecmre d mre tee prem re crpp p, re t ve t teqck d keep tt eve cdece tpe, r te rder w jt evprtegrt d.

at te me tme, te Dremer be w e jded ter mpct u.s. r d amerc eeer.

WoRRiEd WoRKERS:Societ o Poessiol Egieeig

Emploees i aeospce (SPEEa), Itetiol Fedetio

o Poessiol d Techicl Egiees (IFPTE) Locl

2001 io Exective Diecto r Gooth speks t the

ios oce i Settle, Wshigto o Decembe 8, 2010.


BOEING STRUCTURE SUPPLIERS

Sources: International Association of Machinists, BoeingNote: diagrams not to scale

Parts built by the IAM union of Boeing workers

737 ClassicFirst flight:1967

787 DREAMLINER First flight:2009

747 seriesFirst flight:1969

Horizontal

stabilizerAlenia Italy

1

1

Movable

trailing edgeAustralia

Passengerentry doors

Latecoere/France

Fixed & movableleading edgeSpirit/U.S.

WingMitsubishi/Japan

Fixed trailing edgeKawaski/Japan

EnginenacellesGoodrich/U.S.

EngineRolls-Royce/U.K.

Centre fuselageAlenia/Italy

ForwardfuselageSpirit/U.S.

Forwardfuselage

Kawasaki/Japan

WingtipsKAA/Korea

Parts nameCompany/Country Tail fin

Boeing/U.S.

Main landinggear wheel wellKawasaki/Japan

Wing/body fairingBoeing/Canada

OTHERS

Landing gear structureMessier-Dowty/U.K.

Centrewing boxFuji/Japan

Cargo access doorsSaab/Sweden

Rear fuselageVought/U.S.

Wing-to-body fairingBoeing/U.S.

Fuselage

Interiors

Floor panelsFrontalfuselage

Nosegeardoors

Wings

Wing structure

Wings

Engineparts

Fr t 787 Dremer prt pper, cck ere:

h://www.beg./ea/787fa/ev_ea.h
http://www.boeing.com/commercial/787family/dev_team.htmlhttp://www.boeing.com/commercial/787family/dev_team.html


11/11


CoVER PhoTo: Two jp ailies (jaL) Boeig 787 Demlie ets sit idle t Pie Field i Eveett, Wshigto o Decembe 8, 2010 s see om the oo o Boeigs Fte o Flight avitio

Cete.REUTERS/AnThony BolAnTE

Thomso retes 2011. all ights eseved. 47001073 0310repblictio o edistibtio o Thomso retes cotet, icldig b mig o simil mes, ispohibited withot the pio witte coset o Thomso retes. Thomso retes d the Thomsoretes logo e egisteed tdemks d tdemks o Thomso retes d its lited compies.

FoR MoRE inFoRMaTion ConTaCT:

Jim impoco,

EntErprisE Editor, AmEricAs

+1 646 223 8923

[email protected]

clAudiA pArsons,

dEputy EntErprisE Editor

+1 646 223 6282

[email protected]

KylE pEtErson

+312 408 8581

[email protected]

Te Dremer w e devered err ter. ad med te me pe wprked Everett m e te rt td 787 t tke ter pce te ke mter be c ke te jm 747 d terter-re wrkre 737.

bt be empee te Petsd re re cre tter t

crprte ctre te erde te k

amerc wrker d mke ter cmpe ttrctve t pepe eter te

j mrket. Te pe be eder w ee t ter w.

Jd t ttemet -- cd teemed cmmet t Reter -- te cmpd t crtc m t e r prt tee trc.

We mde t m ce t te me

tme -- ew tec, ew de td ce te pp c -- d ttr r t t me t eectver perd tme, te cmp d. rt, we ve ered, d we re ppr er.

(Reprt Ke Peter Tm heper; Edt Jm impc

Cd Pr

liVinG ThE dREAm:

Boeig emploees wok

o the iteio ssembl

o 787 Demlie t

the comps plt i

Eveett, Wshigto, M

19, 2008.REUTERS/RoBERT SoRBo

Special Report: Dreamliner Outsourcing; What Went Wrong?

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Transcript of Special Report: Dreamliner Outsourcing; What Went Wrong?