Thursday, September 8, 2016

Ultra low-cost flights to Iceland, Barcelona from South Florida will launch in 2017

 (WOW)

Starting next spring, a new crop of transatlantic flights — to top European and Nordic destinations — will be available for South Floridians at a fraction of the previous cost.

WOW air, Iceland’s low-cost transatlantic airline, announced Thursday it will begin the first-ever nonstop service between Miami International Airport and Reykjavik, Iceland — plus connecting flights to Europe — in April 2017.

Service to Reykjavik’s KeflavĂ­k International Airport will be available three times a week from MIA for as low as $99 one-way — about a tenth of the cost of current flights to the Nordic country. The airline will offer connecting flights via Iceland to London, Paris, Amsterdam, Berlin, Frankfurt, Dublin, and Copenhagen from $149 one-way, including taxes.

European routes will also be added at Fort Lauderdale-Hollywood International Airport beginning next year, in August 2017.

Budget carrier Norwegian Air Shuttle announced Wednesday it will offer twice weekly flights from Fort Lauderdale to Barcelona, Spain’s Barcelona-El Prat Airport from $189 one-way, including taxes. That’s a discount of more than 25 percent over current fares.

The announcements mark another step in the airlines’ expanding North American footprints.

The Miami-Iceland route is the sixth U.S. destination for WOW since it launched North American flights in May 2015. For MIA, the additional service marks the fourth Nordic country and 23rd route to Europe on the airport’s growing roster.

Barcelona is the seventh city with nonstop service to the U.S. that Norwegian has added to its route network since launching in the U.S. three years ago. The airline added one weekly flight to Paris’ Charles De Gaulle Airport from Fort Lauderdale on July 29, in addition to its London, Copenhagen, Oslo and Stockholm routes from FLL.
 

(Chabeli Herrera - Miami Herald)

Boeing 737 and 787 Profit Gains Will Overwhelm 777 Decline, Analyst Says

Boeing investors may have been scared off by the declining market for wide-bodies, but one analyst says bears are missing improving picture for the 737 and the 787.

Despite the slumping market for wide-body jets, a new report takes a positive view of the outlook for Boeing thanks to improving cash flow, prospects for a higher dividend and a continued strong market for the reliable 737.


In the report, Cowen & Co. analyst Cai von Rumohr reiterated an outperform rating on Boeing and set a price target of $175.

Boeing shares closed Wednesday at $132.64. Year to date, Boeing is down about 8%, making it the second worst performer in the Dow 30. Only Disney, down 11% has done worse. The Dow is up about 6% year to date. Bearish views of Boeing have dominated this year for three reasons, von Rumohr wrote.


Orders for the 777 are declining due to the expected 2020 introduction of the 777X; the 787 program has $27.7 billion in deferred production costs that must be amortized; and "the long air transport upcycle is running out of gas.

"Bears are right to be concerned with the coming decline in the 777's profit contribution," he wrote. "But they don't give full credit to the probable 737 profit ramp, which should offset most of the 777 drop.

"We estimate that 737 gross profit contribution will increase by $1.8B from 2015 to 2019, offsetting most of the 777 decline," he said.

Boeing said it will ramp up monthly 737 production to 52 in 2018. Demand for the world's airplane workhorse remains strong. 


Globally, domestic traffic is up 5.1% year to date, according to the International Air Traffic Association. That is a good sign for the 737 and the Airbus A320, the two narrow-bodies that fly the bulk of the world's domestic routes. Boeing has a backlog of 4,404 orders for the 737 and "delivery positions are oversold through 2019," von Rumohr said.

"737 revenues should rise by an estimated $6B+ from 2015 to 2019, and even with the delivery mix shifting to the MAX, we think profit accrual rates can increase," he said. "Work on the 737 MAX appears to be moving ahead smoothly." First delivery of the 737 MAX is expected in 2017.

Von Rumohr said he anticipates Boeing will increase 737 production to 57 a month in 2019, even as it trims 777 production from seven to four or five a month and moves very slowly to boost 787 production from 12 to the stated goal of 14 a month.

Investors are overly worried about the 787's deferred production costs, von Rumohr said, noting "bears obsess over 787 accounting and argue that BA will have to take a huge forward loss because the program's $27.7B in deferred production costs means that the 869 remaining deliveries in the accounting block will have to amortize $36.1MM per copy to avoid a charge."


He said the deferred costs increased because Boeing spent heavily to make substantial improvements from the 787-8 to the 787-9. But now that the 787-9 is selling at a higher price than the 787-8, the deferred costs will come down more quickly, and they will come down even more quickly when the 787-10 starts to be delivered.

"Investors were mostly unaware of the significant changes in the Dash 9, which BA chose not to highlight likely for fear of alienating Dash 8 users," von Rumohr said. "Hence, they were disappointed by the extended high plateau of quarterly deferred production increases into 2014."

Even at a dozen 787s a month, "787 will turn cash positive with initial amortization of 787 deferred likely in Q3," he said.


Another aircraft that could soon help Boeing's profit picture is the KC-46, the aerial refueling plane being developed from the 767 for the Air Force. The first 18 deliveries are scheduled for 2017. "The KC 46 has been a big drain; they took close to $2 billion in forward losses," von Rumohr said in an interview.

The losses will diminish, he said, and "the level of cash drain will go down and they could start to turn cash positive in late 2018."

Meanwhile, Boeing has hiked its dividend 125% since 2013 while buying back about 6% of shares annually. Add it all up, von Rumohr said, and by 2019 Boeing becomes a stock with cash flow of $15 a share and a dividend of $6.25 a share.

A current dividend yield of 3.3% "offers downside support and makes BA a standout value vs. its peers," he said.


(Ted Reed - The Street)

Wednesday, September 7, 2016

First G500 Production Test Aircraft Takes Flight

Gulfstream G500 (c/n 72005) N505GD taxies at Savannah-Hilton Head International Airport (SAV/KSAV) following her first flight.
(Gulfstream Aerospace)

A Gulfstream G500 dedicated to creating an exceptional cabin experience has completed its first flight.

The G500 departed from Savannah-Hilton/Head International Airport with a three-man crew and cruised for more than four hours at Mach 0.84, well below its maximum Mach of 0.925.

This is the fifth test aircraft produced, and it will be used to evaluate every aspect of the passenger experience, including overall comfort, cabin and galley layout, ergonomic ease, functionality and the passenger interface with cabin electronics. Repetitive operations of all systems during many phases of flight and mission types will be conducted and evaluated.

“The many hours of interior testing this aircraft will undergo, from galley and lavatory use to comfort and cabin health during long flights, help us hone every aspect of flying the G500,” said Mark Burns, president, Gulfstream.

The G500 will feature an industry-leading low cabin altitude and 100 percent fresh air that boost mental awareness and reduce fatigue. Another environmental advantage: The G500’s panoramic oval windows are the same size as those on the Gulfstream G650 and G650ER, which allows for abundant natural light.

Delivery of the first G500 is scheduled for 2018.

(Gulfstream Aerospace)

Monday, September 5, 2016

Delta Airlines McDonnell Douglas MD-95 (Boeing 717-2BD) (55008/5009) N945AT

Taxies at Salt Lake City International Airport (SLC/KSLC) as it readies for a late afternoon departure on June 7, 2016. The aircraft was originally delivered to AirTran Airways on November 27, 1999.

(Photo by Michael Carter)

Alaska Airlines Boeing 737-790 (30164/597) N619AS

Captured arriving at Portland International Airport (PDX/KPDX) on August 4, 2016 sporting the modified winglet artwork in relation to the carriers new livery.

(Photo by Michael Carter)

Hillary Clinton Begins Traveling With Press Corps on 'Hill Force One' Plane

Hillary holds a model of her new campaign aircraft, Boeing 737-86J (30881/1067) N881XA.
(Justin Sullivan - Getty Images) 

Hillary Clinton, who has abstained from the common campaign practice of flying on the same aircraft as her traveling press corps, has landed a new ride, a large jet dubbed Hill Force One, and welcomed reporters on board.

Beginning today -- with just 64 days left until the election -- the Democratic presidential nominee, who has drawn fire for not holding press conferences is replacing her small, private jet with a significantly larger aircraft that she will not only share with her campaign staff, but with Secret Service staffers as well as reporters too.

The new plane was unveiled today with a trip to Ohio and the Quad Cities, a region of four counties in northwest Illinois and Southeastern Iowa.

“I am so happy to have all of you with me,” Clinton said Monday morning in greeting the press on its inaugural flight, adding, “I've been just waiting for this moment.” Clinton also added that she would be back later to take more formal questions from reporters.

The plane is a 14-year-old Boeing 737, made in America and first delivered in 2002 to AirBerlin as D-ABBE, with Clinton’s logo “Stronger Together” on the side. It's equipped with Wi-Fi and broken up into four cabins: one for Clinton and some aides, one for extra staffers, one for her Secret Service detail and one (with roughly 42 seats) for press. The aircraft last served with Orenair as PH-CDG and Corendon Dutch Airlines as PH-BEI.

Until now, Republican presidential candidate Donald Trump's running mate Mike Pence has been the only one of the four presidential and vice presidential nominees to have this set-up.

Clinton's plane today had company from Trump and Pence’s separate planes as it landed on the tarmac today in Cleveland.

Today is also another turning point for the Clinton campaign.

After a month of, what Trump would call, "hiding," Clinton and her surrogates are hitting the trail this Labor Day in full force.

Clinton herself has as many public events today as she's had in the past two weeks. She has an event with her running mate Tim Kaine in Cleveland, and then another in Quad Cities in Iowa. And it's not just Clinton on the road. Kaine, his wife Ann Holton, Vice President Joe Biden, Vermont Sen. Bernie Sanders, and Bill Clinton are all out on the trail today, too.

(Liz Kreutz - ABC News)

Falcon 8X makes LABACE debut

 Dassault Falcon 8X (c/n 401) F-WWQA.
(Dassault) 

Dassault is debuting its Falcon 8X business jet at the Latin American Business Aviation Convention and Exhibition (LABACE) in SĂŁo Paulo, Brazil between 30 August and 1 September, as it seeks to drum up sales for the long-range trijet ahead of its validation by Brazilian certification authority ANAC in the fourth quarter of this year.

Dassault Falcon president and chief executive John Rosanvallon says the Latin American country “has shown strong demand" for the 8X since the programme’s launch in 2014. “Four of the first 20 aircraft are scheduled to be delivered there,” he says. “That’s a great sign of a Brazilian market that might be turning the corner for the better.”

Brazil’s economic downturn has heavily impacted sales of new and used business aircraft. The country has traditionally been a strong market for manufacturers of business jets and turboprops. Flight Fleets Analyzer records an installed base of around 1,500 aircraft in the country – the largest inventory outside of the USA.

The flagship Falcon 8X secured US and European certification in early July, and first deliveries are scheduled in the coming weeks.

In preparation for the 6,450nm (11,900km)-range 8X’s entry into service, Dassault has begun ramping up production at its Bordeaux MĂ©rignac final assembly plant in southwest France. Serial number 29 is now being manufactured at the facility, and 15 aircraft are being outfitted at Dassault’s US completion centre in Little Rock, Arkansas.

(Kate Sarsfield - FlightGlobal News)

United States Air Force McDonnell Douglas F-15C-25-MC Eagle (c/n 580/C110) 79-0041, 173rd FW, Oregon Air National Guard


This gorgeous aircraft is captured arriving at Portland-Hillsboro Airport (HIO/KHIO) on August 5, to take part in the 2016 Oregon Air Show.

(Photos by Michael Carter)

Alaska Airlines Boeing 737-990(ER) (62470/5980) N251AK



This new Alaska Airlines -990(ER) made a special appearance at the 2016 Oregon Air Show by flying a World War II veteran down to Hillsboro Airport (HIO/KHIO) from Seattle (SEA/KSEA) on Saturday August 6, 2016 for a special ceremony in his honor.

The aircraft is captured rolling for takeoff at Hillsboro Airport headed back to Seattle International. 

(Photos by Michael Carter)

Montreal plane spotters have fun as well as boosting airport security

 Plane spotting enthuasist Jean-Charles Hubert looks on as an Air Transat Airbus A330 lands at Montreal's Trudeau Airport, Sunday, July 31, 2016.
(Graham Hughes/The Canadian Press)

Some plane spotters given training, uniform, special number to call in suspicious airport activity

Perched on a ladder with his camera, a scanner tuned to the control tower on the ground beside him, Jean-Charles Hubert doesn't miss much at Montreal's Pierre Elliott Trudeau airport.

Every week, rain or shine, the 41-year-old can be found at the airport with his fellow plane spotters – a group of aviation enthusiasts with a passion for photographing aircrafts.

"It's a bit like a drug,'' said Hubert, wearing a blue ball cap bearing the group's name – the 55th Avenue Spotters, named for one of the roads that runs by the airport.

"I keep telling myself I'm not going to come, but then I find myself back here.''
The group's dedicated presence can even be a boon for security, as far as the airport is concerned.

Hubert says he and some of the other spotters make a point of calling airport security if they notice anything unusual, such as a hole in the fenceline or suspicious human behaviour.

Some other members of the group have had that role somewhat formalized by the airport authorities, who created an "airport watch'' program in 2009 that is modelled after similar programs in Ottawa and Toronto.

Christiane Beaulieu, the Montreal airport's vice-president of communications, says basic training, uniforms and a special phone number to call are provided to the watch's 46 members.

"They know where the airplanes are coming and going, they know how many people are around at any given time,'' Beaulieu said.
She wouldn't say how many incidents the group has reported, but said the airport's security team is "very satisfied'' with the arrangement.

On a recent Sunday afternoon, however, most of the 30 or so visitors at a popular spotting location seemed to be there just to watch the low-flying planes roar by overhead.

They included families with young children and couples sitting in lawn chairs, as well as the ubiquitous photographers.

Although similar plane-watching groups exist in other Canadian cities, including Vancouver, Toronto and Ottawa, Hubert believes Montreal's is probably the most active, with several dozen photographers and some 3,600 Facebook members.

That's partly because Montreal's airport boasts numerous spotting locations near the runways and also because of the administration's support, according to Hubert.

In 2012, the airport opened a public park dedicated to plane watching, which it says is the only one of its kind in Canada.

It features bleachers, a raised bank to help spotters see over the fence as well as signs to help the public identify different kinds of planes.

Not that Hubert needs the help.
He started watching planes when he was 13 and can identify most of them even when they're just distant specks in the sky.

The schedule of takeoff and landings is often predictable, but he's always on the lookout for special aircrafts: the brightly coloured, the rare, the diverted.

While early plane spotters treated the hobby like a collection, trying to record as many tail ID numbers as possible, the 55th Avenue group takes a more artistic approach, striving to capture unique angles and spectacular shots.

"My goal is to have someone who knows nothing about planes to look at the picture and say 'wow,''' Hubert said.

A longtime goal, recently realized, was to get a winter selfie that perfectly captured the image of a plane reflected in his ski goggles.

He said the feeling was pure excitement – one he likens to a fisherman making a big catch.

"Sometimes you have to wait a long time, so when everything finally falls into place it's the best feeling,'' he said.


(Morgan Lowrie - The Canadian Press)

Sunday, September 4, 2016

Southwest Airlines Boeing 737-7H4 (27845/38) N711HK "Herbert D. Kelleher"

Rolls for takeoff on Rwy 30 at Long Beach Airport (LGB/KLGB) on August 24, 2016 bound for Oakland (OAK/KOAK) on a lovely SoCal summer afternoon.

(Photo by Michael Carter)

Alaska Airlines Boeing 737-890 (35091/2086) N562AS

Taxies for departure at Portland International Airport (PDX/KPDX) on August 5, 2016 sporting the carriers new livery.

(Photo by Michael Carter)

United Airlines Boeing 737-924(ER) (32835/2817) N75432 "Eco-Skies" livery



Caught at Portland International Airport (PDX/KPDX) as she makes an early morning departure on August 5, 2016.

(Photos by Michael Carter)

Southwest Airlines Boeing 737-76N (32656/1671) N7710A, ex AirTran N184AT

Taxies towards its departure at Portland International Airport (PDX/KPDX) on August 5, 2016.
(Photo by Michael Carter)

Beech 18S (c/n 4383) N9109R



 
 This gorgeous aircraft is captured departing, then returning to Portland-Hillsboro Airport (HIO/KHIO) on August 5, 2016.

(Photos by Michael Carter) 

Military jet crashes on rise as some cite training and fleet issues

Marine Maj. Sterling Norton, 36, was killed when his F/A-18 Hornet crashed on July 28 during a live-fire nighttime training accident in Southern California.

Less than a week later, another F/A-18 from the same squadron crashed outside Naval Air Station Fallon, Nev. The pilot ejected safely – but it was the squadron’s third F/A-18 crash since October - two of which were fatal.

The Marine Corps, in response, conducted a one-day safety stand-down.

But such accidents are becoming more frequent – amid concerns that insufficient training and an aging fleet hobbled by a shortage of spare parts are contributing factors. A Fox News investigation reveals that, overall, the entire U.S. military saw a 48 percent increase in non-combat aviation crashes in 2014 and 2015 compared with the two prior years, based on press reports.

“They are going up partly because they are not getting the training they should get. They're going up because maintenance is harder and harder to accomplish. They are going up because the airplanes are getting older and older,” said House Armed Services Committee Chairman Mac Thornberry, R-Texas, in an interview with Fox News.

Maj. Norton deployed in combat to Afghanistan in 2012. His commanding officer called him one of his best pilots. According to the Washington Post, a Marine who witnessed the crash said Norton’s jet “broke apart in midair” while in a dive preparing to fire weapons.

"I want to wait for the investigation report. However, these jets are too old and should not be flown anymore," Norton's mother, Mary Anne Vanderhoof, told Fox News.

On Capitol Hill in July, the head of Marine Corps aviation seemed to share her concern.

“I worry about my young aviators that aren't getting the number of hours they need to. And so it's the mishaps that loom over the bow that we don't see coming just now … Will they have the experience to keep that bad thing from happening?" said Lt. Gen. Jon "Dog" Davis.

So far in 2016, there have been nine military aircraft crashes. Four involved Navy F/A-18 Hornet jets. There were 33 total across all branches in 2014 and 2015 – up from just 23 in 2012 and 2013.

The admiral in charge of Navy aviation denies a link between the crashes and the age and readiness of their planes.

"I wouldn't characterize it as a crisis. I get the question a lot of, do you tie it to readiness or a lack of proficiency … and in review of those mishaps, I can't make that connection," said Vice Adm. Mike Shoemaker, speaking in Washington last month.

According to statistics provided by the U.S. Navy, only 21 percent of its early model Navy F-18 Hornets can fly -- and only half of its newer Super Hornets can as well. Over 100 Super Hornets are not flying due to shortages in critical spare parts.

The Navy’s fleet of MH-60 helicopters is not much better. Only 57 percent of its 412 helicopters can fly.

The Navy, like the Marines, is having a hard time finding available jets for its pilots to fly and train in – amid more than $100 billion in defense cuts since 2009, a steady tempo of combat missions, and a delay of the F-18’s replacement, the F-35 Joint Strike Fighter.

Training is another concern. Right now, the Navy is averaging 12-14 flight hours a month for its pilots, according to Shoemaker. The Navy is buying more Super Hornets and hopes to increase that average to 15 hours by December 2017, according to a Navy official who shared a forecast model with Fox News.

Following a Fox News investigation into Marine Corps aviation in April, an interview with the head of Marine Corps aviation reveals some gains, but many problems persist.

Today, only two of the Marine's 12 F-18 Hornet squadrons meet their flying hours, Davis told Fox News. He said they are averaging 11.1 flight hours a month per Marine pilot right now. While it was 8.8 back in March, he said his pilots should average 16 hours a month.

“Our model is all squadrons ready to go,” he said. When asked why his pilots were not getting enough hours in the air he replied, “Not enough airplanes to fly, it’s a simple physics problem.”

Right now, of the Marines' 273 F-18s, only 91 can fly; 88 are waiting for parts.

Thornberry said President Obama has effectively sent more U.S. troops into harm’s way without paying for the increase in costs.

“When the president sends more people to Afghanistan more people to Iraq, he doesn't ask for more money. The costs just come out of the training, the maintenance and the readiness of our force. The problem is getting worse,” he told Fox News.

The Pentagon disagrees.

Lt. Col. James B. Brindle, a Defense Department spokesman, said in a statement, "Ensuring that the force is well-equipped and well-trained to execute critical missions is a priority. We have looked at our data and have not observed an overall trend in the increase of mishaps due to reduced training hours.
 
Annual mishap totals vary for a variety of reasons. Any increases we have observed are too small, and over too short a duration, to categorize."

Marine and Navy F-18s were originally designed for 6,000 flight hours, but they were refurbished and extended to 8,000 hours while waiting for the new Joint Strike Fighter. Some jets may even reach 10,000 hours, according to Navy and Marine Corps officials.

In 2015, the Marine Corps’ aviation mishap rate was three times the Navy’s.

The Air Force, while not suffering from the same shortage of parts, is short 700 pilots, and the secretary of the Air Force said last month it will grow to 1,000 “in just a couple of years from now.”

When asked how quickly the Marine Corps can get more Joint Strike Fighters into the fleet to replace 24-year old F-18s, Davis replied, “I am buying as many as we can afford. The money is not there.”
 
(Lucas Tomlinson - FOX News Politics)

Saturday, September 3, 2016

Japan asks European aviation agency to ensure safety of Rolls-Royce 787 engines

Japan has asked the European Aviation Safety Agency to ensure a problem with Rolls-Royce engines powering Boeing 787 Dreamliners does not repeat to cause flight disruptions or affect safety.

Japan's Ministry of Land Infrastructure Transport and Tourism said on Friday it issued the request after ANA Holdings , Japan's biggest carrier, canceled 18 flights last month to repair corroded turbine blades in the Rolls-Royce engines on some its Dreamliner fleet.

Officials at the EASA were not immediately available for comment.

Since February, three ANA flights have experienced engine trouble, once on a flight from Kuala Lumpur to Tokyo, a second time in March on a jet traveling to Vietnam and most recently on a domestic route in August.

The biggest operator of the carbon composite jet on Tuesday said it would replace the faulty turbine blades in all 100 engines on its 50 aircraft, an operation that could take as long as three years to complete.

Of around 450 Dreamliners in operation worldwide, two fifths use the Rolls-Royce engines. Carriers can choose either the Rolls-Royce engines or General Electric Co's GEnx engines for their Dreamliners.


(Maki Shiraki - Reuters)

Southwest, American Airlines get final approval for Havana flights

The U.S. Department of Transportation has granted final clearance for Southwest Airlines and American Airlines flights to Havana, making the North Texas-based carriers two of eight U.S. airlines to fly to the capital of Cuba beginning as early as this fall.

The final approval came Wednesday, the same day JetBlue completed the first commercial flight between the U.S. and Cuba in more than 50 years. That flight, with 150 passengers, left Fort Lauderdale and landed in the central Cuba city of Santa Clara.

The transportation department’s Wednesday decision finalized its July 7 tentative decision to allocate 20 daily frequencies to U.S. air carriers for scheduled passenger services between the U.S. and Havana. Alaska Airlines, Delta Air Lines, Frontier Airlines, JetBlue Airways, Spirit Airlines and United Airlines got the go-ahead along with Fort Worth-based American and Dallas-based Southwest.

Southwest will serve Havana with three daily flights, combined nonstop service from both Fort Lauderdale and Tampa Bay. As previously authorized by the DOT, Southwest also intends to offer two daily flights to Varadero, and one daily flight to Santa Clara, all nonstop from Fort Lauderdale, the airline said in a statement.

“We appreciate the Department of Transportation’s decision and considerable work to reestablish scheduled service between the two countries,” Southwest’s statement says. “Southwest’s Cuba service will make company history, as well, bringing our world-famous combination of exceptional value and customer service to a ninth country, and adding our 100th city served by Southwest Airlines.”

Southwest said its Cuba fares and flight schedule will be announced in coming days at Southwest.com/Cuba.

In its final order Wednesday, DOT said that it “tentatively found that it could best maximize public benefits by addressing the service needs of the substantial communities that are most likely to benefit — primarily centers of Cuban-American population — while, at the same time, creating a framework for a competitive market structure.”

The agency added that “the record amply supports that the Cuban-American population centers in the United States are the areas most in need of scheduled service to Havana.”

American Airlines will be the second U.S. airline to launch commercial flights to Cuba in decades, with a flight departing from Miami International Airport on Sept. 7.

On that day, American, which has offered charter jets to Cuba for 25 years, will launch its commercial service to the Caribbean island with flights from Miami to Cienfuegos and Holguin. Two days later, American will launch service from Miami to Santa Clara and Camaguey. Service from Miami to Varadero will begin Sept. 11.

Tourism to Cuba still isn’t authorized for U.S. citizens, but travelers can be approved under 12 sanctioned categories of travel.


(Bill Hethcock - Dallas Business Journal)

Boeing’s struggle with 777 assembly robots adds to Everett production snarl

Boeing’s new robotic 777 fuselage-assembly system is gearing up very slowly, with some mishaps requiring rework. That’s compounding supplier issues to cause a buildup of incomplete jobs, slamming 777 final assembly and requiring heavy overtime to keep deliveries on track.

Production of Boeing’s large 777 twinjet in Everett is significantly backed up, with incomplete jobs on each aircraft forcing catch-up work, some of which is being finished only after the jets roll out onto the airfield.

Final-assembly mechanics are slammed. Scrambling to fix the mess, they’ve kept 777 deliveries on track only by working long overtime hours, including weekends, with just two days off a month.

What’s going on? Workers blame the new 777 robotic fuselage assembly system that management has been ramping up.

This critical new technology, which Boeing must get right before the forthcoming 777X, automates the precise drilling and fastening together of fuselage panels for the big moneymaking jet.
Boeing executives insist the robotics — known as Fuselage Automated Upright Build, or FAUB — are not the major hang-up.

“The disruption in final assembly is not just caused by FAUB,” said Jason Clark, Boeing vice president of 777/777X operations, in an interview. “It’s not the major cause.”

Rather, the executives finger supplier issues for much of the incomplete work cascading through and choking the production system. Clark cited the nearly six-week Machinist strike at Triumph Composite Systems in Spokane that ended in late June as one source of parts shortages.

Still, he conceded the robot system is proving painful to set up. Thesystem is gearing up much more slowly than expected and has contributed to the pileup of incomplete work, he said.

“To downstream mechanics, it feels like FAUB,” Clark added. “It looks like something coming out of that shop that isn’t complete, and it’s very disruptive to their work.”

Several final-assembly mechanics said that’s indeed how it looks to them. They spoke on condition that they not be identified for fear of retribution by the company.

“FAUB is a horrible failure,” said one mechanic. “They keep forcing these unfinished, damaged airplanes on us.”

Another veteran employee said each section is coming out of FAUB with hundreds of incomplete jobs. “It’s a nightmare,” he said.

Early last month that view was reinforced when Boeing restarted the robots after pausing the system for several weeks and ran into a major mishap.

Stitching together the forward fuselage of a China Eastern 777 passenger jet, the robots scored a metal skin panel bad enough that it had to be replaced.

Clark said that was a one-off error by the machine’s human operator. It was the only skin panel damaged on the 20 fuselage sections built by FAUB so far, he said.

Once the technology is debugged and matured, he said, the new robotic systemwill be faster, more accurate and more flexible than Boeing’s traditional manufacturing method. Its adjustable tooling will be able to build the new larger 777X fuselages on the same production line now building the current 777 fuselages.

 
“We are changing the way we build the airplane so that we can accommodate the 777X … That’s the flexibility and gain from this,” Clark said. “It’s a little tough in the teething, but as we get through it, it will create the rewards necessary for us to compete.”

“There’s a lot of change,” Clark added. “When you have that, you’ve got a lot of disruption.” 


Inside the FAUB facility

 
Boeing has a dwindling backlog of just 162 current 777s and it will cut back production from 8.3 jets per month now, to 7 jets per month early next year, and then down to 5.5 jets per month in 2018 or 2019.

By then, Boeing will begin transitioning to the 777X, which has 306 orders.

Boeing chose to introduce the automated FAUB system before 777X so it can iron out all the kinks and have a smooth production flow that will reduce risk for the new airplane program.

To make the case that FAUB is progressing despite its troubles, Clark and Brad Zaback, 777 deputy vice president and general manager, invited The Seattle Times to see how the robots are deployed.

 
It’s the first time a journalist has been allowed into the new, 325,000-square-footfacility near the even larger 777X composite wing center on the huge Everett site.

Inside, the first set of FAUB equipment is up and running. Partially assembled fuselages sit on cradles surrounded by metal frames and light tooling that detaches and pulls away from the airframe when the work is done.

Having built 777 aft fuselage sections earlier, the FAUB facility is now producing only forward fuselage sections. Once that’s perfected, the plan is to do both aft and forward sections with separate sets of tools for each.

By 2018, the plan is to build new 777X fuselages on this same line.

The traditional way Boeing still makes these fuselage sections is for mechanics to drill and fasten them together manually while massive, rigid fixed tooling holds the skin panels together.

In FAUB, there is no rigid tooling. Boeing has instructed its 777 fuselage parts suppliers to drill additional holes in the incoming skin panels, frames and floor beams that can be used to line up the pieces for an exact fit.

 

In the first FAUB position, mechanics lever the 14 major panels into place on a cradle atop an automated guided vehicle so that these holes align. The mechanics then tack the panels together with temporary fasteners.

“When we first started, the panels didn’t fit together very well,” said Clark. “We had to go back in our supply chain with our engineers and change it a little bit.”

Once the fuselage section is tacked into shape, it rolls over to the automation cell, where four robots apply permanent fasteners, though only to the heaviest-duty circumferential and longitudinal splices connecting the section — the more difficult work where it’s necessary to insert larger rivets through thicker metal.

One pair of robots drills and fastens in unison on the upper half of the fuselage section — one inside, one outside. Another pair works down below in similar fashion.

The outside robot can insert a rivet while the inside one simultaneously flattens it at the other end to create the fastening.

Once the automated work is complete, the flexible tooling separates and the fuselage section rolls off to the next stage.

 

In two further positions, mechanics manually insert the remaining fasteners and brackets, including those in areas of limited access — such as the confined space under the flight deck.

In the new setting of the FAUB facility, mechanics find this manual work to be slow and difficult.

“It’s not easy on our folks,” said Clark, adding that any unfinished work coming out of FAUB is “a combination of the manual as well as the automation work.” 


Baby steps

In a separate area of the FAUB building, Boeing is now setting up similar though simpler equipment to fasten together the mid-body fuselage sections, which include the center wing box and stubs of the wings.

For this section, the automation installs only two-sided fasteners — no one-piece rivets — so just an outside robot is used, while mechanics chase its work inside, manually installing collars on the fasteners.

The robots used on the mid-fuselage, designed by Mukilteo engineering firm Electroimpact, are the same ones — known as Quadbots — that Boeing uses in South Carolina to fasten the aft fuselage of the 787 Dreamliner.


In theory, the FAUB automation system is designed to handle many different fasteners, from one-piece rivets to various two-piece fasteners and bolts. The goal is that the robots will do the hardest 20 percent of the fastening in each fuselage section.

In practice, Boeing is taking small steps, slowly introducing new elements of the work that haven’t been done previously, and testing each new piece of the process as it does so.

“We are looking at the different types of rivets and we are slowly adding them in one type at a time,” Clark said. “We have not done all the automation on the forward section yet.”

“We run it very, very slow,” he said. “We don’t turn it up to 100 percent until we are absolutely confident.”

Each time engineers complete the painstaking work of testing and debugging the software that tells the robot where the holes go, the results are encouraging, Clark said.

“The quality of the automation is very good,” he said. “That machine drills a perfect hole every single time. It installs a fastener every single time.”

He said it “takes a little more time to learn” how to close the fasteners so they fit with the required precision.

The testing and qualification of the FAUB equipment and processes for Federal Aviation Administration (FAA) certification should be completed over the next several months, he said.

Zaback, the 777 deputy vice president, described a recent example of the slow learning process.

On the first FAUB fuselage section built in August — which workers identified as a Korean Air 777 freighter jet — Boeing for the first time used automation on a particularly curved part of the skin.

But after inserting several hundred rivets, he said engineers saw that the work was not precise enough.

“We saw it and we stopped, and those rivets had to be removed,” Zaback said.

Such rework complicates and slows down the work that comes after. 


Incomplete jobs cascade down

With Boeing production scheduled like clockwork and tied to expected jet deliveries, management policy dictates that incomplete jobs and rework travel ahead on the assembly lines, to be finished later — if necessary out on the field.

“No matter what, the production system moves,” Clark said. “If we’ve got traveled work, we move it.”

“By doing it this way, we contain the disruption within the walls of Boeing. We don’t threaten deliveries,” he added.

Assembly mechanics describe having to work on fuselages with multiple temporary fasteners called “clecos” — which stick out a couple of inches from the skin — so that the aircraft “look like porcupines.”

Boeing says inserting clecos is standard when dealing with traveled work and that the number of clecos on FAUB-built fuselages is not abnormal — and may be as much due to the manual work in the facility as to the robotics.

Clark said the robotics may also produce incomplete jobs not as a result of any defects but because engineers have slowed the system down as they introduce new work.

“As soon as you slow it down, you create a traveled work bubble,” he said. “It’s not a quality issue. It allows us to get through the learning with the new equipment.”

Still, he said it’s not possible that the relatively small number of FAUB fuselages sections being built — one section every other airplane for the moment — is solely to blame for the level of incomplete work that’s been traveling downstream to the 777 mechanics in the main assembly building.

“We’ve had issues with the IAM strike at Triumph in Spokane and notices of quality (problems) from other suppliers,” he said.

Triumph supplies ducting for passenger-cabin ventilation as well as floor panels on the 777.

As for the damage to the skin panel on the China Eastern plane, that was highly exceptional, Clark said.

After a minor change to the system’s software code, someone ran the equipment without first checking via simulation that the robots would still operate as planned.

Clark said Boeing has introduced checks in the operating process so that shouldn’t happen again.

“Is it perfect? No. It’s much harder than we expected,” Clark said. “But we are making inroads on every single line number.”

Boeing will begin to build the first 777X next year. By then, FAUB needs to be much closer to perfect.



(Dominic Gates - The Seattle Times)

Thursday, September 1, 2016

Joe Sutter Dies: 'Father' of Boeing's 747 Jumbo Jet Was 95

Joe Sutter speaks near a model of a 747 jumbo jet.
(AP Photo/Elaine Thompson)


Joe Sutter, the Boeing engineer who ushered in the modern era of long-range travel by spearheading the 747 jumbo jet in the 1960s, has died. He was 95.

“Joe lived an amazing life and was an inspiration – not just to those of us at Boeing, but to the entire aerospace industry,” Ray Conner, chief executive officer of Boeing’s commercial airplane division, told employees in a message announcing the death Tuesday.

Airbus Group SE hailed him via Twitter as “a pioneer in the industry.”

The 747 was the capstone of a career spanning the twilight of piston-engine airliners to Boeing’s rivalry with Airbus four decades later. Starting with a swept-wing prototype in 1954 paving the way for the first U.S. jetliner, Sutter’s stamp was visible on aircraft through the 757 and 767 in the 1980s.

“He was a great engineer,” said Phil Condit, a former chief executive officer of Boeing who was once a member of Sutter’s 747 engineering group. “He dearly, dearly loved that airplane.”

Like the 747, Sutter was a throwback to a time when large, physical products defined U.S. innovation. With Boeing’s survival on the line, Sutter led a team that crafted the jet in less than two-and-a-half years even as he defied the design wishes of the first buyer: Juan Trippe, the Pan American World Airways founder who was then the most powerful person in aviation.

“The aircraft was iconic and so was he,” Richard Aboulafia, a Fairfax, Virginia-based aerospace analyst, said of Sutter. “It was a time of moonshots.”

Sutter retired in 1986 at age 65 as executive vice president in charge of Boeing’s commercial airplane engineering and product development. He served as a senior adviser emeritus for a quarter-century, regularly stopping by a Seattle-area office into his 90s.

“I have lots of ideas on how to develop good airplanes, and I will voice my comments to the fellas,” Sutter said in a 2010 interview. “They listen to me sometimes, and sometimes they don’t. But that’s the give-and-take of Boeing.”

Sutter helped shape the planes that cemented Boeing’s industry dominance while U.S. competitors faltered. He also didn’t shy from defying senior executives. Ordered to fire 1,000 engineers to save money on the 747, Sutter refused and demanded Boeing hire another 800 workers. He later wrote that he was certain he would be fired. He kept his job, and got extra manpower.

“One on one, he was really neat,” ex-CEO Condit said in a 2015 interview. “He could be a bit bombastic in a group.”

Sutter served as second-in-command on the narrow-body 737, which was launched in the 1960s with prodding from Deutsche Lufthansa AG. The jet became Boeing’s best-seller.

His next assignment was the plane envisioned as an aerial ocean liner by Pan Am, then the dominant global carrier. While Trippe wanted a revolutionary double-decker seating 400 people, Boeing saw it as a mere stopgap in the march toward a glittering vision of supersonic travel.

“If ever a program seemed set up for failure, it was mine,” Sutter wrote in his 2006 autobiography, “747: Creating the World’s First Jumbo Jet and Other Adventures From a Life in Aviation.”

To Sutter, Trippe’s insistence on a single-aisle design with two decks doomed the chances for the big plane’s success. Sutter held out for the single-deck, twin-aisle design -- then a novelty but now the standard in long-range jets.

Tensions ran high, Sutter recalled, until the Pan Am chief visited factory mock-ups of the competing concepts. “You made the right decision,” Trippe told Sutter.

The hump-backed, four-engine 747 brought jet-setting to the mass market when it debuted in 1970, featuring globe-girdling range and more than double the capacity of Boeing’s next-largest aircraft.

Joseph F. Sutter was born to Frank and Rosa Sutter in Seattle on March 21, 1921, five years after Boeing was founded. He fell in love with aircraft as a child in Beacon Hill, a working-class neighborhood south of the city’s downtown overlooking the airfield where Boeing tested new planes.

He graduated from the University of Washington in 1943 with a bachelor’s degree in aeronautical engineering and married Nancy French before reporting for duty on the U.S. Navy destroyer escort Edward H. Allen.

Recruited by two plane-makers after World War II, Sutter accepted a job with Douglas Aircraft Co. because it paid $210 a month, $10 more than Boeing. Then he took a short-term post with Boeing in February 1946 so his pregnant wife could deliver their first child in Seattle -- and he never left.

His first assignment was to help work out glitches on the 377 Stratocruiser, Boeing’s last propeller-driven airliner. He went on to work on the Model 367-80, which led to the Boeing 707, the first U.S. jetliner, and then the 727, 737 and 747.

In his final Boeing post, as executive vice president leading engineering and product development for all commercial airplanes, Sutter oversaw the best-selling jumbo variant, the 747-400. Toulouse, France-based Airbus didn’t get its A380 superjumbo into service until 2007. He later served on the presidential commission that investigated the space shuttle Challenger disaster.

“He dedicated two lives” to aerospace, Nico Buchholz, a former Lufthansa executive who pushed for the most-recent 747 version, said in a 2014 interview.

A half century after Pan Am placed the initial jumbo order, Sutter’s creation has logged 1,543 sales. But with interest waning in four-engine models, Boeing earlier this summer conceded it might have to end the 747 program unless customer interest picks up.

In his book, Sutter recounted Charles Lindbergh’s response to the stately jetliner: “You know, this is one of the great ones.”

Sutter’s wife, Nancy, died in 1997. He is survived by three children: Gabrielle Sutter Young, Jonathan Sutter and Adrienne Sutter Craig.


(Newsmax)