Highlights 787 Overview von Karman Award Lecture International Council of Aeronautical Sciences Mark Jenks Vice President, 787 Development The Boeing Company September 18, 2008 Forming g the International Team Global Technology Development Production Progress A Flexible, Efficient Family Most Successful Program Launch in Commercial Aviation Firm orders 900 787 787-8 210-250 passengers (three-class) 7,650 8,200 nmi 14,200 15,200 km 787-3 290-330 passengers (two-class) 2,500 3,050 nmi 4,650 5,650 km 800 NG 737 700 600 500 400 300 A320 787-9 250-290 passengers (three-class) 8,000 8,500 nmi 14,800-15,750 km 200 767 A330 777 100 A340 0 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52 Months after launch 1 Opening a New Era in Fuel Efficiency New Point-to-Point Routes Enabled Fuel consumption per seat 20% Better 225 SEATS 275 SEATS 200 SEATS 250 SEATS 300 SEATS Current Twins Current Quads 350 SEATS 400 SEATS 450 SEATS 500 SEATS 550 SEATS Vancouver - Sao Paulo Seattle - Shanghai San Francisco - Manchester Boston - Athens Tel Aviv - Montreal Munich - Nairobi Geneva - Singapore Dubai - Taipei Madrid - Manila Auckland - Beijing 787 Fuel consumption per trip 787-8 Range Capability From Anchorage 787 Maintenance Cost Advantage Dubai Addis Ababa 767-300 Mumbai Delhi London Casablanca Singapore Hong Kong Tokyo Bali ANCHORAGE New York Mexico City Los Angeles Rio De Janeiro Buenos Aires Airframe maintenance costs per year 30% Sydney Honolulu Bora Bora Lima Santiago 787-88 Auckland 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Years 2
COPYRIGHT 2008 2006 THE BOEING COMPANY An Airplane Passengers Will Enjoy Larger More comfortable Cleaner air Lower cabin altitude Increased humidity Smoother ride Dynamic lighting More convenient Enables more non-stop travel Reduces trip time Setting New Levels of Environmental Leadership Less fuel used Lower emissions Quiet for communities, crews, and passengers Fewer hazardous materials Less waste in production 787 Program Schedule Start of 787-8 787-8 787-9 Program Firm Major First Enters Enters Launch Configuration Assembly Roll Out Flight Service Service 2004 2005 2006 2007 2008 2009 2010 2011 2012 Highlights 787 Overview Forming g the International Team Global Technology Development Production Progress 3 Partners Across the Globe Bring the 787 Together KHI FHI MHI 4
Alenia Labinal Saab Messier-Dowty 5 Zodiac KAL Boeing Limited 787 Partnering Model Evolution of 7E7 Program Global Enterprise Selecting Our Global Partners BCA Lean Global Enterprise Strategic Sourcing Teams (SST) Composite Process Action Team (CPAT) Sonic Cruiser Leadership Team Tour 08/02 12/03 12/01 6
787 Partner Council The Joint Development Phase Launched with structures members 2004 schedule focus Added systems members Systems/structures working together focus Program commitment focus 1 3 5 2 7 4 9 11 Program execution focus 6 13 8 15 17 10 19 12 21 14 23 25 16 27 29 18 31 33 35 20 22 24 26 28 30 32 34 Added interiors members Korean Potluck Golden Week Program Launch Firm Configuration Start of Major Assembly Roll Out 787-8 First Flight 2004 2005 2006 2007 2008 Bastille Day Celebration Working Across the Globe The GCC (Global Collaboration Center) FHI Handa Plant Groundbreaking Handa Plant (Assembly factory) Vice-President Matsuo breaks ground during July 20 ceremony. 7 Facilities Building our Global Enterprise Kawasaki Factory Nagoya, Japan Alenia factory Grottaglie, Italy Mitsubishi Factory Nagoya, Japan FHI Handa Assembly Factory Nagoya, Japan Autoclaves Fiber Placement Machines and Tape Layers KHI Spirit Alenia Vought MHI FHI Image courtesy of aviationimages.com 8
FHI 787 Handa Plant Celebration Highlights 787 Overview Forming g the International Team Global Technology Development Production Progress Innovative Technologies Composites Serve as Primary Structural Material Durable composites Smarter, more electric systems architecture Advanced aerodynamics Next-generation engines Carbon laminate Other Steel 5% 10% Carbon sandwich Other composites Aluminum Titanium Titanium/steel/aluminum Titanium 15% Aluminum 20% Composites 50% Shanahan Farnborough 35 9 Evaluating Alternative Fuselage Architectures Initial Technology Development in Seattle Composite Skin Stringer Advanced Aluminum Alloys Composite Sandwich Concept Fiber Metal Laminates Joint Spar Development Pre-Production Horizontal Stabilizer 10
Side of Body Joint Strain Survey FHI, Utsunomiya Side of Body Joint Testing JAXA, Tokyo Main Landing Gear Fitting Testing KOBELCO, Japan Combined Multi-Axial Loading Tests MHI, Nagasaki/Laboratory Test Set-up 11 Combined Fuselage Pressure and Mechanical Loading Tests Wing Progress Russia, Seattle, Texas Test Lab Successful Section 46 Testing Extensive limit load testing complete Seven ultimate load conditions successfully run Loaded to 200% limit before failure 12
Structures Testing Ongoing Airframe Static Test to Verify Durability Static testing Second 787 airframe to be assembled in Everett Moved out of Final Assembly on April 25 Drop testing Testing to demonstrate structural stability even at rates 150 percent above most-extreme conditions expected in service Highlights Lower Skin LM Machined in the Kobe Shipyards 787 Overview Forming g the International Team Global Technology Development Production Progress 13 World s First Commercial Composite Wing Section 47 Layup Mandrel Wing Ceremony Delivery Ceremony of First Raked Wing Tip February 16, 2007 14
Production ramp-up Dreamlifter Route Structure Section 41 Wichita, KS to Everett, WA Section 44 Grottaglie, Italy to Charleston, SC Section 11/45 Nagoya, Japan to Charleston, SC Joined Section 43-46 Charleston, SC to Everett, WA Joined Section 47-48 Charleston, SC to Everett, WA Horizontal Stabilizer Foggia, Italy to Charleston, SC Section 46 Grottaglie, Italy to Charleston, SC Section 43 Nagoya, Japan to Charleston, SC Wing Nagoya, Japan to Everett, WA 747 Induction LCF Progress 15 LCF Progress LCF First Flight Dreamlifter Progress 787 Final Assembly Factory Flow Everett, WA 16
Final Assembly: Wing-to-Body Join Production Progress 787 Factory Thank You! 787 Dreamliner Premiere 07.08.07 17