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How has Boeing’s B787 dreamliner turned into a nightmare?

How has Boeing's B787 dreamliner turned into a nightmare?

Most aerospace companies provide the highest quality products due to their extensive knowledge and quality control procedures. Boeing is one of the world’s few corporations that consistently produces high-quality products. However, due to design and manufacturing challenges, Boeing has incurred a large loss in recent years. Quality difficulties have plagued not only Boeing but also Airbus.

However, the company will eventually learn from its errors and make improvements. The aviation licensing authorities, on the other hand, may not allow to make such a mistake again; they inspect the manufacturing system and ensure that they fit all safety criteria. Federal Aviation Administrations, for example, must approve aircraft airworthiness for passenger flights in USA. Manufacture should address all of the issues that have arisen and establish standards.

Boeing has not delivered any new 787 passenger jets to airlines since May 2021, when for a second time safety regulators halted deliveries because they found production flaws in the planes, such as unacceptable gaps between fuselage panels. The FAA had also halted 787 deliveries in late 2020 because of production problems.

Boeing Commercial Airplanes developed and manufactures the Boeing 787 Dreamliner, an American wide-body jet airliner. As of February 2022, there are 1,006 Boeing 787 aircraft in airline service, including 377 787-8s, 568 787-9s, and 61 787-10s, with 481 more aircraft on order. In April of 2022.

How has Boeing's B787 dreamliner turned into a nightmare? Jetline Marvel


Boeing appears to have encountered some difficulties in recent years as a result of several manufacturing issues, which Boeing has resolved. It was recently announced as a result of the COVID shutdown and the 737 Max incident. While Boeing is bearing the brunt of the program’s delays, the impact on client airlines for the type must not be disregarded.

The FAA was called in to address issues involving quality control and the production process. The plane’s self-certification powers have been revoked, and the US government is closely inspecting each undeliverable 787. The manufacturer anticipates significant additional programme expenses as a result of the delays, noting today that

How has Boeing's B787 dreamliner turned into a nightmare? Jetline Marvel

File image : Air India

Commercial Airplanes’ first-quarter revenue fell slightly to $4.2 billion, owing to the timing of wide-body deliveries, which was largely offset by greater 737 deliveries. The operating margin of 20.6% incorporates unusual costs and period expenses, such as charges for the effects of the Ukraine conflict and greater research and development costs.

The FAA has advised Boeing to investigate the production system’s operation and any quality issues that may develop throughout the assembly process. The FAA is toughening the restrictions for Boeing after two B737 Max planes crashed owing to a malfunctioning sensor that triggers the controls.

Allegiant Air Orders Up to 100 737 MAX Jets

The FAA indicated in a statement that if Boeing is eventually authorized to resume 787 deliveries, “Airworthiness certificates for all Boeing 787 Dreamliner’s will continue to be issued by the FAA. The agency will be able to assess the effectiveness of Boeing’s efforts to improve the 787 manufacturing process.”


Manufacturing is a key phase for any product because even the tiniest mistake will be repeated across the board. If it is reported early enough, future reworks can be avoided.

According to the FAA letter, small cracks in the construction surrounding the passenger and cargo doors in the aft fuselage part were also identified.

China may lift the ban on B737 MAX aircraft if certain conditions are met.

This is yet another example of tiny gaps discovered during final assembly in the plane’s structure, which have previously been discovered at major fuselage section joins and the forward pressure bulkhead, a dome-shaped structural barrier behind the plane’s nose that is critical to maintaining air pressure within the cockpit and passenger cabin.


Such gaps, which can also occur in metal aero planes, are frequently filled with little pieces of material called shims during assembly. However, during the building of the plane pieces, Boeing suppliers curiously disregarded the gaps.

These components will be obtained from the Leonardo company in Italy. Previously, the FAA alerted the supplier and advised mechanics to verify their own work when assembling the structures, with little or no oversight from quality inspectors.

Boeing evaluating the production rate of B737 max to 31 per month by end of 2022.

More than 1,000 planes are now in the air, according to the memo, and the FAA is concerned about the lack of detailed assembly data on each plane. Boeing submitted its inspection plan, claiming that it would not require FAA approval.


Issues with the lithium-ion batteries hampered early operations, resulting in onboard fires. In January 2013, the US FAA grounded all 787s until the updated battery design was certified in April 2013. There have been no fatalities or hull damage on the 787 as of January 2022. 72 clients had placed orders for 1,510 787 aircraft as of March 2020.

Boeing claims that some titanium 787 parts were unstandardized made over the previous three years, adding to a long list of concerns with the wide-body aeroplane. Two ANA flights had to ground until the problem could be fixed.

July 2022 Boeing release video and showing that how they working for fixing an Fuselage gap and demonstrated that Boeing 787 is safe aircraft and it can be airworthy . Video

Boeing expanded 737 MAX production and deliveries while also submitting a certification plan to the FAA for the 787. Despite the pressures on Boeing’s defense and commercial development programmes, the company is on schedule to create positive cash flow in 2022, and they are concentrating on our performance as they work through certification requirements and bring several major products to production. Leading with safety and quality, they are taking the necessary steps to ensure operational stability, meet customer obligations, and position Boeing for a long-term future.”


Since late 2020, Boeing has nearly completed the global safe return to service of the 737 MAX, with the fleet having flown over one million cumulative flight hours. The 737’s output rate continues to rise, with 31 planes projected to be delivered per month in the second quarter.

The business has submitted the certification plan for the 787 to the FAA. The initial planes have been reworked, and the company is working closely with the FAA to determine when deliveries will resume. The programme is now generating at a very low pace and will do so until deliveries restart, with a gradual return to five per month envisaged over time. The business continues to expect 787 extraordinary expenses of $2 billion, the majority of which will be incurred by the end of 2023, including $312 million in the first quarter.

Boeing has postponed the debut of the B777x aircraft until 2025 due to continuous issues and the suspension of the B787. However, in order to ensure steady deliveries this year, it has increased production rates for the Boeing 737 MAX.

In the comments section below, tell us what you think about the Boeing 787 aircraft troubles.






Boeing 777-9 Begins Certification Flight Testing with FAA Onboard

Boeing 777-9 Begins Certification Flight Testing with FAA Onboard

The 777-9 has commenced certification flight testing at Boeing Field in Seattle. This is a crucial step under the supervision of our regulator to certify the airplane and deliver it to customers worldwide.

Amidst Boeing’s current challenges, the B777X stands out as a project that could revitalize the brand. It is highly anticipated, and Boeing is keen to clear FAA certifications to release it as soon as possible.

Boeing 777-8F vs Airbus A350F: Comparing two Premium aircraft : Click here

The aircraft is two years behind its initial commitment date. During this time, the company has rigorously tested it under various conditions to ensure its readiness for commercial service.


Boeing has announced that the 777X will be used for both passenger and freighter services, depending on customer requirements.

Boeing’s 777X program has achieved a major milestone with the Federal Aviation Administration (FAA) granting approval to begin certification flight tests, marking a significant step towards the aircraft’s entry into commercial service.

Mega Comparison of Boeing 777x vs A350-1000 Aircraft : Click here

The European Union granted approval for this merger in February, and Korean Air anticipates U.S. regulatory approval by the end of October.


Following Airbus’ breakthrough with Korean Air, Reuters reported in April that Korean Air was considering a new Boeing order focused on the 777X, an advanced version of the 777 mini-jumbo.

Boeing 777-9 First certification

The first certification flight test of the 777-9 took place on Friday evening, with FAA personnel onboard alongside Boeing’s pilots and flight test team.

According to The Seattle Times, the aircraft departed from Boeing Field shortly after 6 p.m. and landed nearly two hours later after flying along the Washington and Oregon coast.

The 777X, an upgraded version of the successful 777 twinjet, features new engines and carbon composite wings with folding wingtips to accommodate standard airport gates.


The first variant, the 777-9X, is designed to carry 426 passengers in a two-class configuration for long-haul international flights.

Comparison of two legendary aircraft Boeing 777x vs Boeing 747 aircraft : Click here

Boeing B777x total orders

Boeing has secured 481 orders for the aircraft, with Emirates being the largest customer, having ordered over 200 units. The planemaker has already built and stored 22 777X jets, with an additional six in various stages of assembly in Everett, Washington.

Boeing is close to finalizing a significant deal to sell approximately two dozen 777X jets to Korean Air, with an estimated value ranging from $4 billion to $6 billion, as reported by Reuters.


Industry sources suggest that the agreement could be concluded as early as the Farnborough Airshow in July. Korean Air, South Korea’s largest airline, has been in discussions about returning to Boeing for its long-haul aircraft needs.

The Boeing 777X vs A350 is one of the most popular comparisons among aircraft as of now. The Airbus A350 has been operating for more than eight years, and its promising performance helps airlines in terms of efficiency and customer satisfaction, particularly in noise and vibrations.

The next generation Boeing 777X can fulfill the same requirements, with 777x first delivery given to Emirates Airlines, the launch customer for this aircraft. It remains to be seen how the Boeing 777X vs Airbus A350 will compete against each other in the future.


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