Der Spiegel has written a great perspective piece on Boeing’s Dreamliner. Here are a few of the highlights:
Eight years ago, managers at the American airplane manufacturer Boeing had a brainstorm. Their idea: Build airplanes the same way the automobile industry manufactures cars, with contractors producing entire components that are then assembled in a final step. That dream resulted in Boeing’s new long-range 787, the first model to be built using this modular principle. And perhaps it was that approach that inspired the plane’s name: Dreamliner.
So far, though, not one of the planes, which cost up to $185 million each, has been delivered to buyers.
Hardly any other project, with the exception of Airbus’ A380 wide-body jet, has fueled the imaginations of aviation experts and fans around the world as strongly as Boeing’s hypermodern showcase jet.
When the project officially began in 2003, it looked as if a new era in civilian aviation was about to dawn. Boeing managers promised their passengers more room, better cabin air quality and larger windows made of “smart glass” which could be adjusted to let in different amounts of light. It was all to be made possible by the increased use of a novel composite material called carbon fiber reinforced plastic (CFRP), instead of the traditional aluminum. The efficient new jet was also supposed to consume 20 percent less fuel and be easier to maintain.
Then there was the production process, which seemed even more revolutionary than the technology. According to Boeing’s plans, final assembly of the new jet would take just three days. To achieve that aim, the company even tossed out traditional industry rules which hold that production of complex airplanes is best entrusted to experienced teams and that important components should be constructed at the main production facility.
Instead, Boeing outsourced the production of the aircraft’s components, including important parts such as the plane’s wings and enormous fuselage, to around 50 subcontractors around the world. Boeing CEO James McNerney stated that the company would retain responsibility only for design, development, assembly and customer care. “The R&D investment level and risk-sharing model with suppliers was deemed appropriate at the time,” a Boeing spokesperson says today, in justifying the decision.
But revolutions always require sacrifices. It was a lesson Boeing learned the hard way. Nearly 60 customers worldwide are waiting for the 787, with first delivery now postponed for the seventh time. Even if the first of the 843 jets ordered so far is delivered to All Nippon Airways late this summer as planned, it will prove difficult to make up a delay that now amounts to three years.
Revolutions not only requires sacrifice, they can be extremely bloody. Boeing is clearly going to pay the price by not listening to their internal Most Important Customers (experienced engineers) who never signed on to they radical approach Boeing took. The amazing thing is how risky their approach has been. In an industry with as few a players as airline manufacturing has, quantum leaps in value are not required. Wouldn’t incremental innovation (like using new materials) have sufficed? Instead, they have bet the farm on this and the results are not encouraging.
Or do you think they should have just bitten the bullet and gone all in?