Will New FAA Investigation Halt Boeing 787 Dreamliner Deliveries?

The Federal Aviation Administration (FAA) has launched a new investigation into production quality on the Boeing 787 Dreamliner. The inquiry focuses on potential gaps in fuselage sections. This issue is part of ongoing FAA investigates Boeing 787 scrutiny. The investigation could lead to more inspections. It also threatens to cause Dreamliner delivery delays for airlines globally.

Concerns center on how the large composite 787 fuselage section gaps are joined. These sections are made by suppliers and then mated together. The FAA is verifying if all joins meet strict engineering specifications. This regulatory action highlights the intense Aviation regulatory oversight currently placed on the manufacturer.

History of Boeing 787 Production Quality

This is not the first time the Boeing 787 Dreamliner production quality has been questioned. The widebody program has faced several quality challenges since 2019. These issues primarily involved shimming and out-of-tolerance components. Shims are small pieces of material. They are used to fill tiny gaps between composite structures.

Fuselage Gap Concerns

In late 2020, improper gaps between composite fuselage sections were found. This led to a near-total halt of 787 deliveries. The stoppage lasted for nearly two years, until August 2022. The gaps sometimes exceeded the tiny 0.005-inch tolerance limit. This is roughly the width of a human hair.

More recently, a whistleblower in 2024 raised new claims. They alleged that fuselage sections were improperly fastened. This could potentially lead to premature structural failure over time. Boeing has strongly disputed these specific claims. The company insists the aircraft is safe. However, the FAA confirmed it was investigating the matter.

Separately, in June 2024, Boeing reported finding hundreds of incorrectly installed fasteners on undelivered jets. The company and the FAA stated that in-service aircraft were safe to fly. The focus remains on aircraft in the inventory awaiting delivery.

Industry and Financial Impact

The ongoing Aircraft safety investigation has significant consequences. Reworking the affected aircraft is both time-consuming and costly. Boeing has incurred billions in abnormal costs. The delivery halt between 2020 and 2022 alone cost the company over $6.3 billion.

• Airlines face uncertainty regarding their fleet expansion plans.
• Delays force carriers to keep older jets flying longer.
• Rework on undelivered planes can take weeks per airframe.

Boeing continues to work through a large inventory of undelivered Dreamliners. The pace of these deliveries depends on completing all required rework. The company is also addressing other quality issues on its 737 MAX program. This is part of a broader Boeing production issues history that has intensified regulatory scrutiny.

Regulatory and Market Outlook

The FAA is taking a more aggressive, hands-on approach to oversight. The agency has increased its presence on factory floors. This is to ensure all manufacturing processes adhere strictly to safety standards. The European Union Aviation Safety Agency (EASA) is also closely monitoring the situation. The goal is to maintain the highest levels of safety in Widebody aircraft manufacturing.

This situation provides a competitive advantage to rival manufacturer Airbus. Airlines seeking widebody jets may favor the A350 program due to the 787's ongoing delivery uncertainty. Industry stakeholders are watching for the FAA's final findings. The outcome will determine the scope of mandated inspections. It will also impact the future delivery schedule for the Dreamliner program. For more updates on this and other commercial aviation news, visit flying.flights.

• Safety Status: Boeing and the FAA maintain that in-service 787s are safe to operate, but defects could cause premature aging.
• Financial Cost: The rework and delivery delays have resulted in billions in abnormal costs for Boeing.
• Regulatory Action: The FAA is increasing oversight and has proposed mandatory inspections for certain 787 components due to non-conformances.