Aerospace Supply Chain challenges for planned production rates

Airbus and Boeing have announced production rates for their single-aisle airplanes of 42/mo each and are thinking of going as high as 52/mo. Boeing last week announced a planned rate of 14/mo for the 787. Airbus has plans for 10/mo for the A350 XWB, and is considering a second final assembly line.

Bombardier, Embraer, COMAC, Irkut, and Mitsubishi each have new airplanes coming on line soon. There are more than 22 new and derivative airplanes planned to enter service between now and 2022.

How will the supply chain meet the demands of the OEMs?

It will be tough, says J. C. Hall, the chairman of the Pacific Northwest Aerospace Alliance, headquartered in the Seattle area. PNAA represents small-to-medium suppliers.

We sat down with Hall to get his take on the challenges ahead for the supply chain.

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Production wars coming: Airbus v Boeing

If some industry observers are concerned about the prospect of over-production now, the current state of affairs may only be the tip of the iceberg.

Airbus CEO Fabrice Bergier says he expects to boost production of the A320 and A350 families over the next few years, overtaking Boeing by 2018.

Airbus currently produces the A320 at a rate of 42 per month. The A330 rate is 10/mo and the A380 at 3/mo. Production of the first customer-destined A350 is to begin by the end of this year, with a targeted delivery in the second half of next year. Ramp-up to an initial production target of 10/mo is planned over a four year period, but the wing factory in Broughton, Wales, has a capacity for 13/mo, inferring a greater rate is already planned. Airbus is considering a second A350 production line, largely focused on the A350-1000.

Boeing currently produces the 737 at 38/mo, going to 42/mo next year. The 777 rate is 8.3/mo and the 747-8F/I rate is 1.75/mo. The 767, driven by the USAF tanker, is 1.5/mo. The 787 is ramping up to 10.mo, with a target by year end, but we believe this will be more likely in Q12014.

Boeing has notified the supply chain to consider higher rates for the 737, 767 and 787. We posted the chart below last June, reflecting the higher planning rates.

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Odds and Ends: Bombardier and American; C919 EIS; Europe blinks

Bombardier and American Airlines: Bloomberg has an analysis of the campaign at American Airlines for a large regional jet order, and how vital it is to Bombardier to win the deal. Embraer won three previous important orders from the US major airlines, leaving American the last remaining prize in the near-term.

C919 Entry-into-Service: Reuters has an analysis about the Chinese effort to challenge Airbus and Boeing with the COMAC C919, and the continued challenges to do so. EIS is now figured for 2018.

Europe blinks on emissions: The European Union blinked on its long-running effort to force all airlines to pay a fine if they don’t meet emission standards. The effort met with international resistance, with China leading the way. Chinese orders for Airbus A320s and A330s had been held up. The Chinese earlier ordered the A320s, but still blocked A330 purchases by its airlines. We’ll see how quickly these orders come through.

Odds and Ends: RR, Airbus milestone; C919; first flight videos

Rolls-Royce, Airbus Milestone: Aviation Week reports that the two companies reached a design milestone for the engine on the A350-1000.

C919 nearing ‘critical’ stage: Flight Global reports that the COMAC C919, China’s bid to challenge Airbus and Boeing in the 150-210 seat sector, is nearing a critical design stage. COMAC also discusses some of the issues with its ARJ21 in the article.

First Flight Videos: No introductions needed.

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Busy decade ahead for new, derivative airplane EIS dates

The next decade will see an extraordinary number of new and derivative airplanes entering service, beginning next year with the Boeing 787-9 and ending in 2022 with what we believe will be a replacement for the Airbus A330.

Bombardier’s CS100 is currently planned to enter service in around September next year, 12 months after its first flight on September 16, 2013, but we think EIS will slip to early 2015. Bombardier seems to be laying the groundwork for this in statements that it will reassess the EIS date in a few months.

Beginning with the 787-9, there is a steady stream of EIS dates–and a couple of end-production dates of current generation airplanes.

This chart captures the airplanes and their dates. Most dates are based on firm announcements from the OEMs, but we’ve adjusted some based on market intelligence and our own estimates.

EIS Dates

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The arrows to certain points within years are not necessarily representative of specific timelines within that year. OEMs generally are not too specific about and EIS date, preferring to say “first half” or “second half” or some derivative of ambiguity. The only specific that we’re aware of is Boeing’s revised EIS of the 737 MAX, from 4Q2017 to July 2017. Although the Ascend data base is quite specific, we’ve not attempted to be highly specific in this chart. (Have we been specific enough about all this?)

Readers will note that we have the ARJ21 arrow going to a question mark. This airplane is already seven years late, and supposedly it’s going to enter service next year, but we aren’t banking on this at all. COMAC/AVIC, producer of the ARJ21, has a dismal record of meeting target dates. Accordingly, although COMAC now says the EIS for the C919 is 2017, we’ve got this in 2018–and even this is likely generous.

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China’s closed airspace hasn’t changed much in 20 years

China’s military continues to so control–and close airspace–in China that delays are rampant, this AP story reports. We’re reminded on the era when we were doing business in China, going there nine times in a 4 1/2 year period from December 1988-mid 1993.

Visiting a number of airlines there, one of which was operated by the military, along with CAAC, CASC and the McDonnell Douglas Shanghai factory, we were struck by the low aircraft utilization: only six or seven hours. Western standards were 10 or more. Even then, we were told, the military control of the skies was a key factor. The low utilization rate then clearly contributed to the need to buy more airplanes to meet traffic growth than was necessary. We haven’t seen any data on today’s utilization rate, but we have to believe this nexus remains.

Flying Chinese carriers then was pretty alarming at times. A ramp worker smoked while refueling a plane, with the refueling connection spraying fuel on the ramp. Carry-on baggage was in the aisle on take off. A person was in the lav on take off. We’ve read some stories in recent years that suggest not much has changed.

Back then, getting into China had limited options. We flew to Tokyo and pretty much had to take Air China into Beijing. A direct air route would go over Korea. We couldn’t go through North Korean air space and apparently flying over South Korean to China was then forbidden, so we had to route south around the Korean peninsula, adding a great deal of time to the flight.

The McDonnell Douglas Shanghai factory was primitive even by standards of the day then, well before robotics and moving production lines. The factory was producing one MD-80 a month and the planes were essentially hand-built. This antecedent might be why the MD-80-looking ARJ21 is having such difficulty. The factory drew so much power that parts of Shanghai went brown-out or black-out during the day, an issue presumably long-since overcome in the Shanghai power grid.

The MD-80 plant was supposed to be MDC’s “in” to gain market share. While selling something like 40 MD-80s/90s (if memory serves) to China via this plant, the venture clearly was a failure and the Chinese used the operation to learn a bit about commercial aviation. Embraer had an ERJ plant in China for the same purpose, and likewise came up short of its goal while the Chinese benefited more. The Airbus plant in Tianjin seems to have been more successful, but we don’t think it’s coincidence that the COMAC C919 looks a lot like the A320.

Odds and Ends: New upgrades for the B-52; MRJ delay confirmed; EIS estimates for new airplane programs

Upgrades for the B-52: The USAF and Boeing are upgrading the Boeing B-52 bomber to further extend the service life. The LA Times via the Seattle Times has this story. This is remarkable; the B-52 was designed in 1948 to be the USA’s aerial backbone against the Soviet Union in the Cold War. It bombed Iraq in the 1991 Gulf War and continues to out-perform the B-1B bomber, which was supposed to replace the old gal, nicknamed by some as BUFF.

More on MRJ Delay: Mitsubishi made it official: the MRJ 90 passenger regional jet will be delayed another year. There are several stories via Google News; this Reuters piece is typical. Aviation Week has a good timeline recap.

Here’s how pending new airplane programs now appear to line up for Entry into Service:

Original Current
CS100        Dec-13        e4Q2014*
MRJ       4Q2013           2Q2017
ARJ21           2006  Good Question
C919           2016           2018–>
A320neo Oct-15 Oct-15
737-8 Jul-17 Jul-17
777X e12-2019**
EJet E2           2018               2018
* One analyst suggests early 2015
** Market Intelligence estimate.

We don’t have enough visibility on the Irkut MS-21 for inclusion in the Table.

Here’s a real oddity: A man in underwear broke into the German Chancellor’s airplane.

American-US Airways: Airchive has this long analysis (and it’s only Part 1 of 2), taking a look at the DOJ complaint. It’s 15 pages even after copy-and-paste into Word and re-sized to 10 point type.

China short on re-engine orders, but nearly 400 C919 “commitments”

The Chinese government and airlines have very few orders for the re-engined Airbus A320neo family and Boeing 737 MAX. There are no identified Boeing 737 MAX orders in China and just 19 A320neos.

There are 197 Unidentified MAX orders, some of them rather large. China in the past has placed large Unidentified orders with Boeing that remained so categorized for years, but there is no way to tell if this is the case right now.

Nor has China placed any orders for the Bombardier CSeries despite growing commercial ventures between Bombardier and the C919 developer, COMAC.

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Odds and Ends: The risk on airborne fires; C919 delays; A380 v 747-8I

The Risk of Fire: FlightGlobal has this story about the risk of fires on board (free registration required). The news article is alarming about the risks of lithium-ion batteries, combined with the new composite technology.

The page for the original report is here.

The 70-page report is here.

Among the findings FlightGlobal reports is what we wrote about early this year: if you have a fire on the airplane, you have to get on the ground in a short period of time (15 minutes, according to an Airbus study, 18 minutes according to this new one).

The interaction between the batteries and composites is a concern.

COMAC C919: The Wall Street Journal has an article talking about the anticipated delays of the COMAC C919. This is via Google News, so it should be accessible to Readers. Here is also a short news item from China Daily and one from Bloomberg.

Airbus loses advertising complaint: Remember those Boeing ads promoting its 747-8 as 26% more economical than the A380? Airbus filed a complaint with a UK watchdog agency, which denied the complaint Tuesday. Aviation Week has this article. One of the things that strikes us from the regulator’s decision is its conclusion that customers would, essentially, see past Boeing’s claims.

Boeing’s use of seats counts–notably 467 for the 747-8–supports the math of the advertisement. But Airbus is right that in true airline configuration, the count would be 405 seats, which dramatically alters the Boeing claims.

Regardless, we have previously opined that the comparison is ridiculous. Given the large differences in the size of the airplanes, comparing the 748 with the A380 is like comparing the 737-700 with the A321. Boeing is cheeky to make the comparison and Airbus fell for it. This debate is hardly worthy of two world-class companies,

Rather than engaging in a debate over seat-based economics, Airbus has a clear upper hand in these numbers: airlines have purchased 262 A380s and only 40 747-8Is. These are the only numbers that count and with these, Airbus clearly has the better advertisement.

Update: AirInsight has some statistics to look at.

C919 program in trouble

COMAC’s bid to develop a 150-200 passenger jet is in trouble.

According to this report, CFM doesn’t plan to proceed with an assembly line within China for the LEAP-1C that will power the C919. Concerns over intellectual property and the business case for the airplane are cited.

According to this article, GKN of Europe, which was to build the horizontal tail assembly, isn’t going to.

The airplane was supposed to enter service in 2016 and we already figured a delay of at least two years. Given the regional ARJ21 is already around seven years late, and still not certified, we think the two years is probably going to move to the right substantially.

If we’re generous and look at a 2020 EIS, this means the C919–an Airbus A320 look-alike–would enter service five years after the A320neo and three years after the Boeing 737 MAX. The airplane is also going to trail in sophistication.

Boeing officials as recently as this year still believe China will develop viable, commercially competitive airliners within the next 25-50 years. The ARJ21 program has been a disaster and it we anticipated that the C919 would be better than the ARJ21 (a low bar, to be sure), not truly competitive with the A320 and 737 but COMAC’s “makee-learn” airliner. It’s looking like this will be a disastrous program, too.