Great and Gray news about MAX 8 production increases

Boeing Max 8 plant door
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Boeing on way back with the Max 8

Production ramping up

Reduce Lean Manufacturing and increase QC/QA?

GREAT NEWS: Boeing has all the airworthiness approvals from the FAA; the Company has the demand for its B-737 Max 8 aircraft; and the below announcement indicates that the Renton plant will be delivering 31 new planes in 2Q 2022, 40 by the end of 2023, and a target of 47 for monthly deliveries in 2024.

green planes with airline tails

GRAY NEWS: it is only implicit that the quality controls  production line and supply chain intake will have staffing and rigorous criteria/record increases commensurate to the new production goals. That is not to say that the Boeing PR should have clarified these aspects; the FAA’s production certificate is designed to track such transitions. Boeing has had to file its generic plans to address increased production and the FAA has established management guidelines for its inspectors to assure that the PC PC application and FAA Certificate Management statementholder is meeting its obligations.

 

The Max 8 disgrace primarily  involved a failure in the design of the software for the Maneuvering CharacteristicsItalian QC report Augmentation System (MCAS).There were some issues on the quality control over intake of parts.

[There were frequent complaints about the B-787  Dreamliners’ quality at the North Charleston, SC facility.]   ,

Although not heavily publicized, the Boeing headaches may be attributable to its adoption of Lean Manufacturing processes. It hired Walter Odisho, a former Toyota Motor Corp. executive who joined the planemaker in 2013 as a vice president in charge of manufacturing, safety, and quality. It was suggested back in 2019 by a digest devoted to all forms of QC management that—

“One would imagine that the world’s leading aerospace company, responsible for designing and manufacturing more than 10,000 of today’s commercial airliners, would have rigorous quality control protocols in place. Not surprising, recent revelations have presented grave concerns about Boeing’s internal management and highlight the need to keep workplace standards in the spotlight.

A closer look at Boeing’s recent shortcomings have revealed a larger problem. “It’s clear that Boeing has insufficient process controls in place,” says Michael DiLeo, president of the {stet} . “While Boeing has a very strong safety record, incidents like this show the importance of a continuous improvement methodology being in place. If tools are being left on aircraft and no one notices, this is a sign that there is a breakdown of standards within the manufacturing process.”

The Harvard Business Review has written extensively on what can be gleaned from Japan’s cultural practice of attention to detail, something that could prove beneficial to Boeing in light of its current position. Roper said it best in his statement to the press: “It’s simply following processes that Boeing has on the books, and having a culture all the way down to the mechanic level that embraces them.”

Japanese auto manufacturer Toyota has mastered this concept in what has been dubbed the Toyota Production System (TPS), by focusing on what takes place at the micro-level. Toyota’s success is due largely in part to TPS, or what in the Western world is refers to as the lean manufacturing model and the 5S system.”

Ed Clark Jr.[1], a Boeing executive with significant experience in production and the added perspective of having worked for several airlines, replaced Mr. Odisho. Clearly his focus is and has been on quality in every aspect of Boeing’s QC systems. Other recent appointments[2] show that the company’s senior executives have, indeed, reemphasized THE MOST CRITICAL ASPECT of AIRCRAFT MANUFACTURING!!! Strict Adherence to SMS at every level of the company is a most effective way to attain the highest levels of safety.

Boeing SMS statement

 


 

Boeing Plans To Ramp 737 MAX Output To 31 Planes A Month

BY GAURAV JOSHI

Max Production Line

 

The US planemaker hopes to increase production to fulfill its commitment of delivering thousands of MAX airplanes on order.

The Boeing 737 MAX program is gradually getting back on track, with the company predicting an increase in output in the coming months. The two tragic MAX crashes inBoeing Corporation 2018 and 2019 within months of each other led to a 20-month grounding of the type. But with airlines becoming comfortable with the type again, Boeing foresees an uptick in the MAX output to meet the demand.

31 planes a month

Boeing is hopeful of ramping up production of its 737 MAX airplanes in the second quarter as it looks to push out the thousands of unfilled orders of the type. Last month, the US plane manufacturer released its first quarter results, detailing several key figures and plans, including revenue, 787 Dreamliner certification plans, and delivery targets.

Among several striking figures present in the report were also projections about the production of the 737 MAX airplanes. The report was hopeful of increasing the output of the MAX planes in the coming months as airlines around the world get ready to expand operations. The report stated,

31 deliveries goal“Boeing has nearly completed the global safe return to service of the 737 MAX and the fleet has flown more than one million total flight hours since late 2020. The 737 production rate continues to increase and is expected to increase to 31 airplanes per month during the second quarter.”

Further increase

 

Boeing’s projection of 30+ MAX deliveries isn’t an overnight development. In fact, the planemaker plans to increase the figure to more than 40 by the end of 2023. According to a Reuters report published in March, two people familiar with the matter said that Boeing has preliminary plans to boost production of the 737 MAX to around 47 per month by the end of next year.

In January, Boeing said that it was working to clear an inventory of 335 MAX airplanes that had piled up following two fatal crashes of the jet and the resulting grounding for 20 months. It estimated most of those jets would be delivered by the end of 2023.

With COVID loosening its grip worldwide and many airlines looking to explore options for narrowbody fleet development, both Airbus and Boeing have been pitching their aircraft aggressively by offering lucrative deals.

However, it remains to be seen whether the global supply-chain industry, which took a massive beating during the peak of the pandemic, will be robust enough to meet Boeing’s aggressive production estimates.

Boeing global source map

4000+ unfilled orders

According to the data released by Boeing, it has 4,138 unfilled orders for the MAX family of aircraft (including the yet-to-be certified MAX 10) as of March 31st, 2022. Airlines from across the world are waiting to induct the type into their fleet following the successful recertification of the aircraft.

In late January, Chief Financial Officer Brian West said the 737 program was pushing out planes at a rate of 27 per month and was on track to reach 31 per month “fairly soon.” Sources revealed to Reuters that Boeing was preparing to nearly double production by the end of 2023.

The planemaker plans to increase to around 38 narrowbody jets monthly during the first half of 2023 and reach about 47 jets per month in the second half of 2023.

With a commitment to deliver these many planes, here’s hoping that Boeing lives up to its projections in the months to come.

What are your views on this? Please share your thoughts in the comment section.

[1] Clark, who joined Boeing in 2006, steps in the top 737 role after having been vice-president of global technical operations for Boeing Global Services (BGS).

Previously, Clark was vice-president of commercial services programmes within BGS and vice-president of the company’s Global Fleet Care material logistics business.

He has also been chief engineer and director of “737 airplane integration” and of 737NG systems, and chief 737 mechanic, according to Boeing’s website.

Prior to joining Boeing, Clark worked 16 years in the airline industry, including at Southwest Airlines as manager of systems engineering and at TWA as manager of 757 acquisitions.

 

[2] Carole Murray is vice president of Total Quality for Boeing Commercial Airplanes, chair of the Boeing Quality Operations Council and a member of the company’s Executive Council. She leads the focus on driving quality excellence and adopting standardized best practices across the global organization. Within Commercial Airplanes, she drives efforts to ensure first-pass quality throughout the value stream. Murray is responsible for supporting the relationship between Boeing and the Federal Aviation Administration, and for ensuring continuous improvements in the company’s Quality Management System and driving its integration with the Boeing Safety Management System. .Scott Stocker is the vice president of Manufacturing and Safety for Boeing Commercial Airplanes. In this role, he is responsible for ensuring the Commercial Airplanes global production system consistently operates in an aligned, integrated and effective manner.

 

max 8 manu line

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