Leeham News and Analysis
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Outlook 2023: stabilizing operations at Boeing
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By Vincent Valery and Scott Hamilton
Introduction
Jan. 5, 2023, © Leeham News: LNA wrote a year ago that resuming Boeing 787 deliveries was among the top 2022 priorities for the American OEM. Despite taking longer than envisioned (until August), the resumption of Dreamliner deliveries proved to be the high point of 2022 for Boeing Commercial Aviation (BCA).
The resumption of 737 MAX operations in China has still not materialized, and clearing the inventory of aircraft produced during the grounding is taking longer than envisioned. Boeing does not expect Chinese carriers to take delivery of their 140 737 MAXes for several years.
While Boeing launched the 777-8F, the 777X had another significant entry into service delay. The EIS is scheduled for 2025, around five years later than envisioned at the program launch in 2013. In October, a new problem with the giant GE9X engine emerged. Analysis is underway by GE. Whether there will be any additional impact on EIS remains to be seen.
Certification of the 737 MAX 7 and MAX 10 appears to be on a path for success. In November, Sen. Maria Cantwell of Washington State proposed extending the deadline from year-end 2022 for compliance with legislative requirements to install a new system called EICAS. EICAS monitors the 737’s systems and guides pilots in handling faults. EICAS is not on the already-certified MAX 8 and MAX 9. The legislation was passed with the assumption that the MAX 7 and 10 would be certified before the effective date.
However, the factors that most impacted BCA’s ability to generate cash flows were supply chain issues and labor shortages. Boeing has still not stabilized production on the 737 line at the announced goal of 31 per month.
In light of all the above, what lies ahead for Boeing in 2023?
Summary
- Critical to stabilize aircraft production;
- Financial drag from the Defense, Space & Security division;
- Avoiding more material certification delays;
- EcoAviation and lack of new product developments;
- Competing for orders without launching a new aircraft
Outlook 2023: Labor shortages continue to plague aerospace
Boeing 777 final assembly line in Everett (WA). Credit: Leeham News.
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By Bryan Corliss
Jan. 4, 2023, © Leeham News: Some aerospace suppliers say the industry is dealing with a shortage of production workers, as well as engineers. Airbus, Boeing and other manufacturers, including engine companies, complain they can’t get to desired production rates because of, in part, a labor shortage.
It’s part of a broader phenomenon across all manufacturing, with one industry group saying there’s an immediate need for 2.1 million factory workers right now.
In some circumstances, this has meant raising wages. In Wichita, the “Aerospace Capital of the World,” there’s a bidding war going on for skilled aerospace mechanics. In Puget Sound, Boeing had to go back to the bargaining table with the Machinists Union in 2019, to negotiate $4-an-hour pay increases for entry-level workers. In Charleston (SC), Boeing reportedly struggles with a higher-than-normal attrition rate as workers leave for higher-paying jobs.
It seems inevitable that the lack of experienced workers will make it harder for companies to deliver parts and finished goods on time, and the absolute need to raise pay will cut into margins. Both these factors could very well be a drag on profits, even as airlines clamor for new aircraft that will increase manufacturers’ revenues.
Summary:
- Analysts warn of ‘labor headwinds’
- Spirit faced with ‘dynamic’ labor environment
- Boeing: 100 new mechanics a week?
- New-hire pay about the same as retail
- High turnover causes supply chain problems
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NTSB issues critique of Ethiopia’s final report of Boeing 737 MAX 2019 crash
By Scott Hamilton
Dec. 27, 2022, © Leeham News: The US National Transportation Safety Board (NTSB) today issued a critique of the newly released final investigation report of the Ethiopian government of the March 10, 2019, crash of a Boeing 737 MAX.
Ethiopian Airlines flight ET302 came five months after Lion Air flight JT610, a MAX, crashed. Both accidents began when the Maneuvering Characteristics Augmentation System (MCAS) activated following a failure of the single Angle of Attack (AOA) sensor to which it was tied malfunctioned (JT610) or failed (ET302).
Boeing issued a notice to MAX operators after the Lion Air crash outlining proper procedures pilots should follow in case MCAS erroneously activated again. The Ethiopian government investigation placed the blame for the crash on Boeing. The NTSB’s critique concluded the pilots failed to follow Boeing recommendations and should be partly held responsible for the probable cause of the crash. Had they followed procedure, the NTSB concludes the pilots could have successfully flown through the emergency.
Pontifications: LNA’s Top 10 stories of 2022
Dec. 26, 2022, © Leeham News: This year has been a year of recovery.
By Scott Hamilton
Recovery from the COVID-19 pandemic. Recovery from shortages in the supply chain, layoffs during the pandemic and from financial losses. Boeing continues to struggle in its recovery from the 2019 grounding of the 737 MAX and 2020 suspension of deliveries of the 787.
This year saw a resumption of the big international European air shows since the pandemic—Farnborough. There was great anticipation that Boeing was working on new airplane programs in earnest for the first time in three years.
And disappointments.
Here’s a review of the Top 10 stories LNA published, by readership.
Leeham News in addition to Twitter, Facebook and Linkedin, may now be found on Post.news here and on Mastodon here.
Suppliers expect Boeing to increase 787 rates next year
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By Bryan Corliss
Dec. 19, 2023, © Leeham News: Boeing suppliers are planning to increase their output to support the OEM’s plan to deliver five new-built 787s a month at some point in 2023.
Boeing wants to increase the production rate of the 787 to 5/mo by the end of 2023 and to 10/mo by 2025. The supply chain must hurry to prepare. Credit: Leeham News.
It will be challenging for the top-tier suppliers to scale up operations dramatically. They’ll have to train and maintain larger teams of workers, while also ensuring that their own lower-tier suppliers have the capacity to deliver parts and components on time.
One executive warned investors this fall that the challenges in the year ahead will be greater than the ones the industry faced delivering record numbers of planes before the pandemic.
Summary:
- Howmet: ‘Back of the year, at around 5 per month’
- Suppliers want more lead time given challenges
- Whole supply chain is under stress
Leeham News in addition to Twitter, Facebook and Linkedin, may now be found on Post.news here and on Mastodon here.
United orders 100 Boeing 787s, 100 Boeing 737s, defers Airbus A350 again
Dec. 13, 2022, © Leeham News: United Airlines today announced a massive order for 100 Boeing 787s and 100 Boeing 737 MAXes. Sub-types weren’t announced. Neither were the engine types for the 787s, which are powered by either GE Aerospace’s GEnx or Rolls-Royce Trent 1000.
An order for 45 Airbus A350s was deferred again, this time to at least 2030. Deliveries were to begin in 2027. The order had been deferred at least twice previously. Reuters reported “United CEO Scott Kirby told reporters ‘the right time for 350 versus (787) conversation is when we’re replacing the bulk of the 777s, which really doesn’t begin to the end of the decade.’” Most observers believe this order will be canceled eventually.
Related articles
At least one more big airline order, Air India, is expected before the end of the year.
Pontifications: The Queen is Dead. Long live the Queen.
By Scott Hamilton
Dec. 12, 2022, © Leeham News: The 1,574th Boeing 747 rolled off the production line last Tuesday. The last one, after 53 years of continuous production. The iconic aircraft was known as the Queen of the Skies.
The larger A380 didn’t replace the 747. McDonnell Douglas’s DC-10 and MD-11 didn’t replace it. The Lockheed L-1011 didn’t replace it. Neither did Boeing’s own 777-300ER. And neither will the 777X. The 777-X does not replace the 747—it succeeds the 747. I don’t think that anyone will characterize the 777X as “the Queen of the Skies.” The X looks like any other airplane. The 747 look is unique (a well-worn, overused word that in this case applies) and iconic. It has a nose door. The 777XF does not.
The Queen is Dead. Long live the Queen.
The last Boeing 747 to be built rolled off the Everett factory line Dec. 6, 2022. Line No. 1574 is for Atlas Air. After painting, a decal of legendary engineer Joe Sutter, the father of the 747, will be applied to the starboard side. Photo credit: Leeham News.
As it turns out, there was a debate within Boeing as far back as 2004 about whether to cancel the 747 program then. The 777-300ER was just entering service. There was a recognition within Boeing that the -300ER was the beginning of the end for the 747.
I tell this story in my book, Air Wars, The Global Combat Between Airbus and Boeing. Also in the book is the story about how Boeing tried to launch the 747-500 and 747-600, without success. Airbus won this competition, launching the A380 with Singapore Airlines and in the process killing the 747 derivatives. But Phil Condit, then the CEO of Boeing, wasn’t upset. Something else was in the hopper.
Below is a synopsis of these stories, excerpted from Air Wars.
HOTR: Tuesday’s Boeing announcement may give indication of A350 future at United
By the Leeham News Team
Dec. 9, 2022, © Leeham News: The engine selection on a big Boeing 787 to be announced Tuesday may be the most definitive signal yet of what United Airlines will do with its oft-deferred Airbus A350 order.
United is considered certain at some point to cancel its orders for 45 A350s. This order has been deferred several times. The new order to be announced Tuesday for up to 100 or more Boeing 787s adds to the more than 60 already in the fleet. United clearly doesn’t need a large fleet of 787s and a smaller fleet of A350s.
But canceling the Airbus order is not without some cost. It’s believed that penalties to Airbus are manageable. These also may be mitigated by an order for A321neos. This can solve Airbus’s concerns. But it does nothing for Rolls-Royce, which provides the engines for the A350s.
Rolls is not an engine supplier for the A321neo. United’s swapping the A350 for the A321 means Rolls loses that future business. What’s the mitigation for Rolls?
United may split the engine order for the 787 between incumbent GE Aerospace and Rolls. If the engine selection is announced Tuesday and the order is split, this will be the clearest indication yet that the A350 order will be history. United and Boeing scheduled a press conference at the 787 production and assembly plant in Charleston (SC).
HOTR: Big airplane orders race toward year end
Dec. 8, 2022, © Leeham News: A year-end aircraft order rush will benefit Airbus and Boeing, according to what LNA is hearing.
Air India
Airbus appears in line to win 50-100 A350 orders from Air India. Boeing appears in line to win an order from the carrier for 100 new-build 737 MAXes and—get this—40 MAXes that were built for China and which have been in storage since 2019. As previously reported, there were about 140 MAXes built for the Chinese. Boeing said in September it couldn’t wait any longer for China to reopen the domestic market to Boeing for the MAXes. Remarketing the airplanes began then.
The Boeing order could be signed as early as this week or next. The Airbus deal is expected by year-end.
Saudi Arabia
Saudi Arabia is expected to agree to an order for around 50 A350s. The new airline, RIA, which will compete with the current flag carrier, Saudi, is expected to be the prime beneficiary. Airbus hopes to conclude the deal by year’s end if not earlier.
Boeing is not in line for an order this year, according to what HOTR hears. But negotiations begin soon.
The Economics of the 767 and A330 at Seven and Eight abreast
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By Bjorn Fehrm
Introduction
Dec. 8, 2022, © Leeham News: In a previous article, we started speculating what an NMA type of aircraft would look like based on a Boeing 767 cross-section. An airliner’s cross-section decides the design of a large number of parts in an airplane.
In essence, a fuselage is a tube with a constant cross-section where the constant parts are repeated framewise to form the fuselage. It’s finished with a tapering forward cockpit and a rear tapering empennage.
We now look at what could have been a passenger version of an NMA that would have used the Boeing 767 cross-section with adaptations. To understand its economic impact, we make a comparison where we take a standard 767-300ER, then modify it to an NMA type fuselage and compare it to the competition in the size class, the A330-200 and -800.
As before, we do this by flying the world’s busiest long-haul route, London Heathrow, to New York JFK.
Summary
- An NMA based on an improved 767 fuselage cross-section would have been a very competitive airliner
- I would be the ideal replacement for the Boeing 757, 767, and 787-8.